Industry Overview
What are castings?
A casting is a metal part formed by pouring molten iron, steel, aluminum, zinc, titianium, magnesium, copper, brass, bronze or cobalt, in nearly all cases from recycled materials, into a mold or die. Virtually any metal that can be melted can and is cast. Sometimes these castings are used as produced, but more often they are machined or heat-treated and used as components of assembled products.
Why is metalcasting considered the backbone of American industry?
The metalcasting industry plays a critical role in every major manufacturing sector in the United States -- whether it be energy, transportation, agriculture, aerospace or national defense. Metalcasting is unique among metal-forming processes. Metalcasters can produce complex components in any metal, ranging in weight from several tons to less than an ounce.
It is estimated that the average American is never more than ten feet away from a cast part. Artificial heart valves, propellers for aircraft carriers, golf clubs and auto parts are just a few examples of the wide variety of engineered components cast by U.S. foundries.
Today, 2,300 foundries across the nation manufacture castings. U.S. foundries are world-class leaders offering cutting edge technologies and the highest levels of productivity and quality available anywhere in the world. A majority of casting companies are small- and medium-sized businesses. These foundries fulfill a specialty niche, casting unique products or filling small but highly customized orders. Their craftmanship and quality cannot be matched.
Foundries know what competition, quality, customer satisfaction and business survival is all about. They've had to develop expertise in all of these areas. Their business and the jobs they provide depend on it! Our entire industry is proud to provide American manufacturers with the highest quality cast components.
For an overview of metalcasting throughout the ages, order “History of the Metalcasting Industry” from the American Foundry Society
What is the economic impact of the foundry industry?
Here is a brief look at the U.S. metalcasting industry and its significant impact on the nation:
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Directly provides over 200,000 well-paying jobs
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2,300 foundries located in 49 states
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80% of foundries are small businesses with fewer than 100 employees -- with only 6% employing more than 250 people
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Indirectly supports the employment of thousand working in the supplier base and our many end-use customer industries
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Shipped over 14 million tons of castings with a value in excess of $33 billion in 2005
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Castings are used in 90% of all manufactured goods and in all manufacturing machinery
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Foundries consume 15-20 million tons of recycled scrap metal annually -- giving new life to products that would otherwise go to landfills
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Metalcasters use and reuse 100 million tons of sand annually. Only 6-10% can no longer be used in the foundry process and becomes available for beneficial reuse.
What kinds of products do foundries make?
Automotive
Automobiles and other transportation equipment use nearly 35% of all castings produced. Engine blocks, braking components and piston are just a few of the cast parts used in motor vehicles.
In addition to the many iron castings used in autos, consumption of aluminum castings in motor vehicles continues to grow at a rapid rate. This has helped reduce overall vehicle weight, improving gas mileage. U.S.-made cars contain about 150 pounds of strong, lightweight aluminum castings.
Construction Industry
Every home contains more than a ton of castings from bathtubs, pipes, sinks and fixtures to the furnace, air conditioner and other home appliances. And, castings are also an essential component of construction equipment.
Defense
The metalcasting industry is essential to the national defense of our country. Approximately 10% of all castings are produced soley for military application. Tanks, planes, ships, weapons and a myriad of other military hardware contain thousands of cast parts. The figures do not begin to include the dual-use applications that support the military.
Other
Other significant applications for cast parts are in power tools, sporting goods, municipal water and sewer systems and oil and gas pipelines.
For More Information.
See "About Metalcasting" on the American Foundry Society website, or contact the Metalcasting Trade Associations listed under RESOURCES.