a metalcasting marriage - institute of cast metals engineers trends 2007.pdf · headlines as new...

2 Global Casting Trends May 2007

In the metalcasting universe, this Global Casting Trends Supplement is a marriage of the two preeminent information resources in our industry—MODERN CASTING and Foundry Trade Journal—with the goal of delivering to you the current state of the global metalcasting industry.

As we stand in 2007, the global metalcasting industry again finds itself at a crossroads. An industry that once was dominated by production in the US, Western Europe and the former USSR now finds itself diversified across the globe. The US and Western Europe still account for a lion’s share of casting production globally, but these powers have been eclipsed by China’s total tonnage. Regions like India, Brazil, Mexico, Eastern Europe and Turkey also continue to receive headlines as new plants and casting production gravitates to where our customers’ assembly plants are being constructed.

But while many view this diversification as competition among the various nations to secure casting orders, the reality is that the global metalcasting industry must come together to overcome the real competition—fabricated parts, powdered metals, forgings and alternative materials such as plastics. Our industry must work to educate our customer base on the benefits of metalcasting and the geometric complexities it can achieve compared to other part-forming processes. In addition, our industry must look to automate and utilize the most advanced technologies possible to become leaders of manufacturing. Only through these two efforts will our industry truly grow in the future.

With GIFA ’07 in Dusseldorf, Germany, this June, the leaders of our industry from all parts of the globe again will be in one place to help shape our technological future. Whether these leaders are from the US, Europe or Asia, we all must embrace the innovations presented at this event as opportunities to increase productivity and profitability while also providing more effectively engineered cast components to our customers.

Through the marriage of MODERN CASTING and Foundry Trade Journal for this Global Casting Trends Supplement, we have tried to build upon each others’ strengths to produce a product that will engage the global metalcasting industry. Every day in the industry, many of our technology and raw material suppliers also are building on one another’s stengths. Hopefully, metalcasters will begin to follow the lead.

Thank you for your continued readership of MODERN CASTING and Foundry Trade Journal. We hope to continue to be your resource for years to come.

A Metalcasting Marriage

MODERN CASTINGSchaumburg, Illinois, U.S.A.

Alfred Spada, [email protected]

Shannon Kruse, Senior Editor [email protected]

Shea Gibbs, Assistant Editor [email protected]

Michael Berrafato, Art Director [email protected]

Barbara Jackowski, Manager of Customer Service [email protected]

Rolf Petersen, Publisher [email protected]

Foundry Trade Journal West Midlands, UK

Lynn Postle, [email protected]

Sam Jones, [email protected]

Yvonne Marriott, Publishing [email protected]

When you think of great marriages, specific examples come to mind. Anthony and Cleopatra. Wine and cheese. Cope and drag.

Global Casting Trends May 2007 3

May 2007

Contents 4 ALUMINIUM, DUCTILE IRON GAINING IN WORLD MARKET

Global casting production is at an all time high - but which countries are at the head of the pack? The latest statistics give an indication of how the industry is developing.

16 SOMETHING FOR EVERYONE There are a number of factors affecting the cast metals industry

in all parts of the world. We take a look at how, by working together, the industry can compete against other production methods to continue providing first class solutions for its customers.

19 TIMELINE OF CASTING TECHNOLOGY Take a look at the history of the casting process.

31 CALENDAR OF INDUSTRY EVENTS What’s happening throughout the cast metals industry post GIFA

2007 and during 2008.

Advertiser’s IndexABB ...............................................................30Ajax .............................................................IBCBrock Solutions .............................................29Can-Eng ........................................................22Capital Refractoris ........................................23Carbo Ceramics ..............................................8CMH Manufacturing ......................................32CMI Novacast ................................................13Didion ......................................................... IFCFS&D .............................................................21General Kinematics .........................................7Gradient Lens ...............................................31

Inductotherm ............................................. OBCKoins ............................................................18Morgan MMS .................................................12Palmer ..........................................................25Pangborn ......................................................15ProMetal .......................................................26Schaefer Furnaces .........................................14Unimin ..........................................................11Vulcan ............................................................1WFO ..............................................................17X1-Recall .......................................................FC

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A MODERN CASTING Staff ReportA 2005 census of world casting production conducted by MODERN CASTING magazine shows China in a firm position as the top casting producing nation (in terms of tonnage), producing double the shipment tonnage of the next closest nation, the US But despite its large lead over the rest of the metalcasting nations, China wasn’t always the top producer.

In 1966, when the first census of world casting production was conducted by MODERN CASTING, the global metalcasting industry reflected the technological and industrial race between the U.S. and U.S.S.R. At the time, the U.S. lagged behind Russia by less than 2 million metric tons and was gaining ground. While the two countries’ production hovered near the 20 million mark, the other top-three nations, Great Britain, Japan and Germany, were producing between 4.5 and 5 million tons.

Since then, the economic and political landscape of the global metalcasting industry has seen its share of ebbs and flows. A look at past censuses reveals a historical glimpse of the industry (Table 1). In the first year of the census, Germany, England, Japan and the U.S.S.R.—countries that were forced to rebuild following World War II—showed how they capitalised on new moulding equipment, casting technologies and markets to join the U.S. as the five top metalcasting nations.

Today, global casting production is at its highest. Shipments are forecast to reach 90 million tons in 2008, but tonnage produced in both Russia and the U.S. is less than it was in 1966. Russia reported 7.62 million tons of shipments for 2005, while the U.S. produced 12.9 million tons. Tonnage doesn’t necessarily correlate with number of castings shipped since advanced

metalcasting engineering has resulted in the ability to build lighter. And Russia and the U.S. continue to be at the top of the pack production-wise. But the days of 20 million tons of castings are gone. By the most recent census, Russia, Japan and the U.S. still rank in the top five nations but stand in the ever-spanning shadow of China.

Meanwhile, countries like Brazil, India and China have shown massive increases. India’s production has grown 165% since 1966, putting the country at fifth in production for 2005. Brazil has increased from 440,000 tons to nearly 3 million tons. And China, which was excluded in the first census, produced 24.4 million tons in 2005—11.5 million more than the next closest nation, the U.S.

China, whose production grew from a reported 218,200 tons in 1975 to 4.4 million tons in 1986, 11.3 million tons in 1995 and 24.4

Global casting production is at its highest, with total tonnage forecast to reach 90 million tons in 2008

Aluminium, Ductile Iron Gaining in World Market


million tons in 2005, is expected to gain nearly 30% of the global market by 2008. Western Europe is expected to maintain the second highest market share with 18.5%, while the U.S. share drops to just under 15%. Eleven countries and regions produce more than 97% of the world’s metal castings, but most nations are losing market share while China grows. A few other countries—Brazil, Mexico and Korea—continue to gain (Table 2).

Material TrendsProduction by nation isn’t the only metalcasting landscape that has changed. In 1966, the global metalcasting industry was largely dominated by grey iron castings. Grey iron remains the largest sector for production, but its chunk of the globe has shrunk. Once making up 92% of all iron production and 75% of total shipments, its annual shipment numbers have grown at a slower pace

than ductile iron castings. In 2005, grey iron castings made up 66% of total iron castings; ductile iron had a full 32% share.

Nonferrous castings also have gained ground. In 1966, 96% of production was ferrous casting, while 4%, or 3.7 million tons, were nonferrous. In 2005, total ferrous castings reached 70.6 million tons, while nonferrous reached 14.6 million—18% of total global production.

The growth trends for grey iron, ductile iron and aluminium are forecast to continue in the coming years. According to Stratecasts Inc., a firm focusing on domestic and international forecasting and trends analysis and strategic planning, total world casting shipments are expected to increase annually by 2.4% to 90 million tons in 2008 (Table 3). Aluminium casting shipments are expected to grow at 5% a year. Similarly, ductile iron is expected to grow 3.8% annually, but grey iron should have a slower, 1.3% growth, due to the conversions of automotive applications to aluminium and pipe applications to ductile iron (Table 4).

Region BreakdownWestern EuropeTable 5 shows the forecast growth and declines of grey iron by country in Western Europe. Grey iron consumption in motor vehicles is forecast to decline at a rate of 1.2% annually to 2 million tons in 2008, despite the 2% per year growth in motor vehicle production. Engine head production is now 90% aluminium, and the grey iron share in blocks has dropped below 50% and is expected to drop to 30% by 2008. Diesel engine usage in passenger cars has reached 80% in France and near 50% in Germany, thus forestalling complete substitution of aluminium for iron.

Although Western Europe is forecast to see growth in several market sectors, an annual decline of 0.1% is forecast to 2008. Diesel engine castings should see a 3.5% per year growth based on continued growth in truck and car production. Construction and plant engineering applications also are expected to show growth to 2008.

Ductile iron growth is forecast at 2.6% per year, led by a rise in vehicular use and increases in construction, plant engineering and

farm equipment applications. Table 6 shows the forecast for ductile iron by country. Aluminium casting shipments are forecast to grow 2.9% to 2.97 million tons in 2008. Table 7 shows the forecast for aluminium by country.

GermanyThe German economy has had minimal growth in recent years. A 2.5% increase to the GDP by 2008 is forecast, but unemployment remains a major problem. The domestic demand for castings is expected to rise in 2006, 2007 and 2008, with private and public consumption peaking in 2008.

The production of grey iron castings is expected to decrease to 2.2 million tons in 2008 from 2.4 million tons in 2004, a 2% drop per year, as engine block and cylinder head conversions to aluminium accelerate. Ductile iron is forecast to grow from 1.4 million tons to 1.5 million tons in 2008. However, ductile iron consumption in vehicular parts is forecast to decline as applications are converted to lighter metals.

Aluminium casting shipments are forecast to rise from 716,000 tons in 2004 to 768,000 tons by 2008.

United KingdomThough unemployment has decreased in recent years, few casting facilities have modernised to improve their competitiveness. No barriers to imports nor domestic subsidies to improve exports exist. Declining demand has caused capacity to reduce drastically in the last six years.

The production of grey iron is expected to continue to decline as conversion to aluminium and ductile iron continues and exports stay low. Ductile iron shipments are expected to increase to 420,000 tons in 2008, while aluminium casting shipments are forecast to grow to 225,000 tons.

ItalyItaly continues to lead in the production of aluminium castings. Led by automotive diecast applications, a growth to 930,000 tons is forecast for 2008—the highest in Europe. A resurgence in motor vehicle production is forecast for the next couple of years. Motor vehicle production, which declined to levels of 1.1 million units a couple of years ago, is expected to rise to 1.4 million units by 2008.


FranceMotor vehicle production is forecast to rise from 3.35 million vehicles in 2004 to 3.98 million in 2008.

Grey iron casting shipments are expected to decline to a low of 867,000 tons despite the high percentage of diesel engines in France. Ductile iron is forecast to grow from its 2004 low to 1.1 million tons in 2008.

Aluminium casting shipments from French facilities are forecast to increase yearly to 400,000 tons in 2008.

1966 1975 1986 1995 2000 2005

Total shipments (tons): 63,260,410 72,947,695 57,737,284 69,747,750 67,750,239 85,741,078Total iron (tons): 51,779,058 56,034,794 49,369,040 54,622,199 51,128,711 61,613,677% of iron shipments that are grey iron: 92.3% 85.7% 76.4% 72.7% 72.4% 66%% of iron shipments that are ductile iron: 3.7% 9.3% 21.4% 23.5% 25.6% 31.8%Total ferrous (tons): 60,738,944 67,409,502 52,660,907 61,283,382 57,498,395 70,616,401Total nonferrous (tons): 3,739,855 5,548,183 5,076,377 8,464,368 10,251,844 14,601,031% of shipments that are ferrous: 96% 92% 91% 88% 85% 82%% of shipments that are nonferrous: 4% 8% 9% 12% 15% 18%

Table 1. Census Trends from 1966 through 2005

1966 - Top 5 nations: 1. USSR (21.5 million tons); 2. U.S. (19.6 million tons); 3. Great Britain (4.9 million tons); 4. West Germany (4.7 million tons); 5. Japan (4.4 million tons)

1975 - Top 5 nations: 1. USSR (24 million tons); 2. U.S. (16 million tons); 3. Japan (5.5 million tons); 4. West Germany (4.3 million tons); 5.Great Britain (3.5 million tons)

1986 - Top 5 nations: 1. USSR (11.1 million tons without steel and nonferrous reported); 2. U.S. (10.1 million tons); 3. Japan (6.5 million tons); 4. China (4.5 million tons); 5. West Germany (4 million tons)

1995 - Top 5 nations: 1. U.S. (14.4 million tons); 2. China (11.3 million tons); 3. CIS (former USSR) (10.9 million tons); 4. Japan (7 million tons); 5. Germany (4.1 million tons)

2000 - Top 5 nations: 1. China (14 million tons); 2. U.S. (13.1 million tons); 3. Japan (6.3 million tons); 4. Russia (6.2 million tons); 5. Germany (4.5 million tons)

2005 - Top 5 nations: 1. China (24.4 million tons); 2. U.S. (12.9 million tons); 3. Russia (7.6 million tons); 4. Japan (6.7 million tons); 5. India (6.1 million tons)

Table 2. Forecast of Shipments of All Metal Castings with Estimated Market Share of Major Countries & Regions (000 metric tons)

Table 3. Forecast of Total Worldwide Metal Casting Shipments (000 metric tons)

SpainThe Spanish automotive industry is expected to expand from 3.1 million units in 2004 to 3.3 million in 2008. Because of the expected conversion to aluminium, grey and ductile iron casting shipments are forecast to drop through to 2008. But ductile iron is expected to begin a rise in 2008 to 630,000 tons. As exports increase, aluminium casting shipments are expected to rise to more than 200,000 tons in 2008.

PortugalLack of casting capacity is likely to keep shipments low; however, export potential is forecast to spur ductile iron production to 80,000 tons by 2008.

TurkeyAn increase in capacity and competitiveness in the production of iron and aluminium castings continue to make Turkey a key player in metal casting production in Europe. Grey iron casting shipments are forecast to rise to 720,000 tons in 2008 from 475,000 tons in 2004. Ductile iron growth to 350,000 also is forecast. Aluminium casting shipments are expected to rise to 70,000 tons in 2008.

ChinaGrey iron shipments are forecast to increase to 12.75 million tons in 2008. Ductile iron shipments are forecast to increase to 6.7 million tons as exports increase and pipe and construction castings are substituted

Table 3. Forecast of Total Worldwide Metal Casting Shipments (000 metric tons)

Metal 2004 2006 2008Gray Iron 40,319 41,480 42,530Ductile Iron 19,760 21,482 22,584Malleable Iron 1,190 1,160 1,100Steel 6,920 7,154 7,230Aluminium 10,208 11,203 12,423Other Nonferrous 2,450 2,580 2,700Investment 1,007 1,960 1,100TOTAL 81,854 86,119 90,067

Table 2. Forecast of Shipments of All Metal Castings with Estimated Market Share of Major

Country 2004 (%) 2006 (%) 2008 (%)China 23,164 (28.3) 24,630 (28.6) 26,620 (29.6)Western Europe 15,390 (18.8) 16,190 (18.8) 16,660 (18.5)United States 12,340 (15.1) 12,995 (15.1) 13,316 (14.8)Japan 6,790 (8.3) 7,100 (8.2) 7,140 (7.9)Russia 6,548 (8.0) 6,550 (7.6) 6,460 (7.2)India 4,830 (5.9) 5,090 (6.0) 5,390 (6.0)Brazil 2,950 (3.6) 3,195 (3.7) 3,520 (3.9)Mexico 2,292 (2.8) 2,520 (2.9) 2,780 (3.1)Eastern Europe 2,046 (2.5) 2,325 (2.7) 2,612 (2.9)Korea 1,965 (2.4) 2,100 (2.4) 2,390 (2.7)Canada 982 (1.2) 1,000 (1.2) 1,030 (1.1)Other 2,557 (3.1) 2,424 (2.8) 2,149 (2.4)TOTAL 81,854 (100) 86,119 (100) 90,067 (100)


2004 2006 2008Asia GI DI Al GI DI Al GI DI AlChina 11,267 5,603 1,650 12,050 6,100 1,800 12,750 6,700 2,000Japan 2,660 1,895 1,310 2,560 2,150 1,400 2,450 2,180 1,580India 3,180 442 300 3,225 480 350 3,350 520 410Korea 957 557 115 1,000 600 140 1,100 700 160Taiwan 792 215 261 800 225 290 820 240 350EuropeGermany 2,421 1,428 716 2,250 1,474 720 2,226 1,520 763France 943 980 330 891 1,098 385 867 1,119 400Italy 943 486 828 945 520 890 940 550 930UK 572 362 180 590 390 206 626 420 225Spain 506 532 130 564 570 200 563 630 220Turkey 475 308 52 640 320 62 720 350 70Russia 4,200 340 500 4,100 400 550 4,000 440 600North AmericaUnited States 4,265 4,023 1,968 4,311 4,266 2,134 4,288 4,403 2,251Mexico 1,100 270 540 1,150 310 600 1,200 350 700Canada 333 150 240 320 170 260 300 180 300South AmericaBrazil 1,730 597 160 1,850 620 180 1,800 650 200Other 3,975 1,572 928 4,234 1,789 1,036 4,530 2,032 1,264TOTAL 40,319 19,760 10,208 41,480 21,482 11,203 42,530 22,984 12,423

for grey iron. As shown in Table 8, motor vehicle

applications dominate the market for iron and aluminium castings. Led by aluminium usage in automotive applications, shipments of aluminium castings are expected to reach 2 million tons by 2008.

JapanBelow average private consumption for eight years through 2005 kept the GDP down and resulted in low casting production, as shown in Tables 9-12. But an economic turnaround should spur increases in casting shipments.

The continued conversion of iron

vehicle applications to aluminium is forecast to bring grey iron shipments to a low of 2.45 million tons. Ductile iron shipments are expected to rise to 2.18 million tons, and aluminium die castings are forecast to grow to 1.1 million tons, while permanent mould and sand usage rises to 586,000 tons.

TaiwanAfter three down years, the improvement in the economy and rise in imports is expected to increase the GDP. Though grey iron production is expected to show only minimal growth, ductile iron shipments are

forecast to grow to 240,000 tons by 2008. Aluminium casting production is forecast to rise from 261,000 tons in 2004 to 350,000 tons in 2008.

KoreaDespite a strengthening of the won, casting shipments continue to grow. Grey iron, ductile iron and aluminium shipments all are forecast to increase.

IndiaIndia’s car production is expected to double in six years, thus spurring growth in the economy. Subsidising of metalcasting facilities continues to support casting exports. Global

Country 2000 2001 2002 2003 2004 2005 2006 2007 2008Austria 63 62 52 48 50 55 55 58 60Belgium 81 80 78 81 71 80 75 78 80Finland 54 57 56 52 38 40 42 43 44France 1,085 932 924 910 943 897 891 879 867Germany 2,180 2,303 2,253 2,296 2,421 2,399 2,250 2,234 2,226Italy 1,119 966 933 907 913 939 945 955 940Netherlands 58 66 60 61 63 70 70 70 70Norway 28 24 20 17 15 18 18 20 20Portugal 44 34 35 39 29 32 34 38 40Spain 460 576 592 498 506 540 564 566 563Sweden 194 169 157 158 178 170 180 182 182Switzerland 46 42 29 27 29 30 35 50 50Turkey 690 615 620 592 475 610 640 700 720UK 710 519 545 537 572 586 590 612 526Other 200 200 100 129 140 150 170 200 190TOTAL 7,012 6,645 6,454 6,343 6,473 6,507 6,559 6,665 6,578

Table 4. Forecast of Worldwide Shipments of Iron and Aluminium Castings (000 metric tons)

Table 5. Forecast of Grey Iron Casting Shipments in Western Europe by Country (000 metric tons)


market share is expected to increase to 6%.

Eastern EuropeThe forecast growth of passenger car production from 2.8 million vehicles in 2004 to 3.3 million in 2008 is expected to spur casting growth to 2.6 million tons and 2.9% market share worldwide. Led by Poland’s growth to 120,000 tons of grey iron and 40,000 tons of ductile iron and Russia’s 600,000 tons of grey iron castings, shipments are forecast at 1.1 million tons in 2006.

RussiaMarket share in worldwide production is forecast to decline from 8% to 7.2% as ingot mould tonnage drops and conversion to aluminium increases.

BrazilBrazil has a large population of moderately skilled workers with low productivity and very low wages. Technology, particularly in aluminium casting, is top level, and there is

Table 6. Forecast of Ductile Iron Casting Shipments in Western Europe by Country (000 metric tons)

Table 7. Forecast of Aluminium Casting Shipments in Western Europe by Country (000 metric tons)

Table 8. Forecast of Iron & Aluminium Shipments in China in 2006 & 2008 (000 metric tons)

an excellent supply of metal ore. Additionally, Brazil has bauxite plants for aluminium pig production. Casting production is forecast to increase, further increasing Brazil’s market share to 3.9%.

MexicoThe metalcasting industry is

supported by an inexpensive labour pool and high demand for castings due to an expanding automobile industry and local content laws. The industry is hampered by a shortage of materials used in the casting industry, but the nation is expected to further increase casting production due to its excellent capability

Table 6. Forecast of Ductile Iron Casting Shipments in Western Europe by Country (000 metric tons)

Country 2000 2001 2002 2003 2004 2005 2006 2007 2008Austria 110 100 110 100 120 118 122 124 124Belgium 38 19 19 15 16 17 18 20 20Finland 46 44 43 39 50 50 54 56 60France 1,069 1,080 1,232 1,160 900 1,051 1,098 1,118 1,119Germany 1,270 1,269 1,277 1,342 1,428 1,440 1,474 1,560 1,520Italy 407 379 444 458 486 500 520 565 550Netherlands 70 60 60 60 78 80 80 85 90Norway 39 45 44 37 42 48 48 50 50Portugal 45 52 52 53 53 60 60 80 80Spain 500 617 643 410 532 550 570 590 630Sweden 55 57 57 55 60 56 62 70 75Switzerland 74 63 51 46 51 56 56 60 60Turkey 130 132 139 187 308 310 320 330 350UK 540 316 326 342 362 376 390 400 420Other 260 260 130 170 220 220 230 240 250TOTAL 4,799 4,493 4,627 4,474 4,786 4,932 5,102 5,258 5,398

Table 7. Forecast of Aluminium Casting Shipments in Western Europe by Country (000 metric tons)

Country 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008Germany 598 646 620 661 670 716 718 720 740 768Italy 599 680 751 777 790 828 840 890 910 930France 281 349 340 370 329 330 350 385 392 400UK 169 159 160 170 180 189 190 206 210 225Spain 120 120 253 266 132 130 160 200 210 220Austria 75 90 90 90 104 109 110 110 115 120Sweden 40 42 40 43 37 45 50 51 55 56Netherlands 18 18 17 18 18 18 19 20 21 22Other 60 70 80 80 80 180 180 185 187 190TOTAL 1,988 2,382 2,368 2,497 2,357 2,553 2,637 2,789 2,863 2,965

Table 8. Forecast of Iron & Aluminium Shipments in China in 2006 & 2008 (000 metric tons)

Market Grey Iron Ductile Iron Aluminium 2006 2008 2006 2008 2006 2008Automotive 3,550 3,760 1,400 1,540 1,450 1,620Locomotive 260 275Farm & Machinery 1550 1640 400 440Machine Tool 920 975Valves & Spec. Machines 260 280 150 160Construction & Mining Machinery 730 780 150 170Electrical Power Machinery 250 270Ingot Mould 900 930Pipe & Fittings 2,580 2,740 2,300 2,525Leisure 150 160Other 1,050 1,100 1,700 1,865 200 220TOTAL 12,050 12,750 6,100 6,700 1,800* 2,000*1.15 million tons of die castings

** 4.7 million tons of steel, malleable iron, bronze and other nonferrous castings in 2006. 5.2 million tons in 2008


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Table 9. Forecast of Grey Iron Production in Japan (000 metric tons)

Table 10. Forecast of Ductile Iron Production in Japan (000 metric tons)

Table 9. Forecast of Grey Iron Production in Japan (000 metric tons)

Industry 2000 2001 2002 2003 2004 2005 2006 2007 2008Industrial Mach.&Eng. Material 490 460 450 480 520 500 510 500 500Machinery forMining & Const. 65 59 58 60 70 70 80 80 95Metalworking Mach.& Machine Tool 120 105 100 112 130 130 125 130 130Rolls & Ingot Molds 60 55 50 56 60 50 40 30 20Other Machinery 125 112 105 125 130 130 140 145 150Electric Machinery &Telecommunications 80 70 70 83 90 80 80 60 50Automotive Parts& Components 1,480 1,370 1,389 1,389 1,440 1,400 1,350 1,300 1,250Other Vehicles 90 80 70 75 100 90 90 100 100Other 130 85 68 85 120 150 145 155 155TOTAL 2,640 2,396 2,351 2,456 2,660 2,600 2,560 2,500 2,450

Table 10. Forecast of Ductile Iron Production in Japan (000 metric tons)

Industry 2000 2001 2002 2003 2004 2005 2006 2007 2008Industrial Mach. &Eng. Material 160 147 135 140 152 162 172 174 150Machinery forMining & Const. 110 95 90 95 100 105 110 115 120Machine Tool 10 10 10 10 10 11 11 11 11Rolls & Ingot Molds 20 17 18 19 20 21 22 20 20Other Machinery 8 8 8 8 9 9 9 9 9Electric Machinery 16 15 16 16 17 18 18 18 18Automotive 800 780 800 850 900 950 990 980 970Other Vehicle 40 38 30 30 32 34 35 40 40Other 94 77 55 52 70 70 73 75 77Pipe 680 620 580 600 585 680 710 720 720TOTAL 1,938 1,897 1,742 1,931 1,895 2,060 2,150 2,180 2,180


Table 11. Forecast of Aluminium Die Casting Production in Japan (000 metric tons)

Table 12. Forecast of Aluminium Permanent Mould & Sand Casting Production in Japan (000 metric tons)

to produce aluminium and iron engine castings. Aluminium casting shipments are forecast to grow to 700,000 tons by 2008, and ductile iron shipments are forecast to reach 350,000 tons.

CanadaCanada’s weak currency and productive labour pool has made its facilities highly competitive. Aluminium and ductile iron casting

shipments are expected to increase to 300,000 and 180,000 tons by 2008.

United StatesDespite a decrease in light vehicle production in 2006, metal casting shipments rose more than 1.5% over 2005 to 14,615,000 tons. Peak production of medium to heavy trucks and freight cars spurred increases in shipments of ferrous

castings, but lowering production in these market sectors is forecast to result in declines in grey iron and steel castings through 2008 of 1.7% and 11.4%.

Ductile iron casting shipments, however, are forecast to continue gaining in the next two years and grow 0.5% in the long term. Aluminium casting shipments are expected to rise 2% in 2007 and grow by 4.5% through 2008.

Table 11. Forecast of Aluminium Die Casting Production in Japan (000 metric tons)

Industry 2000 2001 2002 2003 2004 2005 2006 2007 2008Industrial Machine &Eng. Material 55 50 52 57 63 67 71 74 89Electrical Machinery 45 40 42 43 47 50 53 58 60Automotive 500 500 521 539 592 625 660 680 720Motorcycles 55 50 52 54 59 62 65 68 70Other 135 120 125 127 140 148 155 160 165TOTAL 790 760 792 823 981 952 1,004 1,038 1,095

Table 12. Forecast of Aluminium Permanent Mould & Sand Casting Production in Japan (000 metric tons)

Industry 2000 2001 2002 2003 2004 2005 2006 2007 2008Industrial Machine 16 15 16 17 19 20 21 21 22Electric Machinery 8 8 8 8 8 9 9 9 9Automotive 304 280 291 301 331 348 360 380 400Other Motor Vehicle 10 10 10 10 11 12 13 14 15Other 76 97 100 104 114 120 125 150 160TOTAL 414 410 425 440 483 509 528 554 586


A Foundry Trade Journal Report

The foundry industry has stabilised in recent years following a period of consolidation, global developments, fluctuations in the availability and cost of raw materials, and the emergence of new markets and new applications.

Barriers to international trade have been broken down and with the rapid development of information technology systems, instant access to designs and specifications has resulted in an internationally competitive market-place.

The export of goods is a significant part of business nowadays and is a contributing factor in the increase in plant operating levels within our industry. As foundries work to capacity to achieve challenging delivery schedules, a number

Something for EVERYONEof issues threaten to affect performance and all important bottom-line – raw material prices, cost and supply of utilities, the impact of climate change on legislative reform and the need to design ever-more complex shapes.

The increase in export activity has a considerable effect on transportation and energy consumption, which in turn has an effect on component cost. Having developed partnerships in lower cost economies, many foundries now outsource some production. Other casters rely on ‘added value’ to help them stand out from the crowd.

But there is little need for concern. Looking at the statistics, the number of cast components is on the increase, and the trend towards lighter weight components continues. The supply chain has never been more important, and the need to support all of the above with a quality workforce that is both educated and experienced is fundamental to the industry’s future success.

The increasing efficiency of casting methods is reliant upon intelligent process design and top-notch engineering. Without this innovation, the cast metals industry will be unable to compete with other disciplines.

Technical cooperation between nations is therefore fundamental to the success of the industry as a whole, as is the further investment in applied research and development focusing on practical problems that need addressing.

There are a number of internationally-recognised research bodies and many universities and technical colleges that utilise grant funding and commercial funding to investigate the process and production methods used in our industry to find the most efficient and commercially viable options. The industry’s ability to tap into these resources is crucial.

The World Foundrymen Organization (WFO) is the leading international technical body tasked with coordinating the efforts of its 33 member associations for the benefit of the industry as a whole. As part of this function the WFO commissions a number of foundrymen and metallurgists to serve on various committees throughout the world to look at specific topics of interest to its member countries. The list of WFO commissions and reports on their findings can be obtained from the WFO direct at www.thewfo.com

The automotive industry is still very much the driving force for the global foundry industry, with approximately 67% of global casting production destined for this sector. In recent times there have been a number of closures of automotive plants in Europe with many manufacturers relocating their high volume production to Asia and the Far East. In the Foundry Trade Journal December 2006 issue, it was stated that by 2010 some 54% of all vehicle production would originate from low labour cost countries.

One way to counteract the low labour cost competition is to mechanise many of the labour


intensive jobs in the foundry and automation continues to play a major role in the development of the industry. Automation and the further development of process capabilities is highlighted at GIFA 2007, where suppliers have a worldwide stage to showcase their products and processes.

Clearly the boom in developing countries will itself lead to increased global demand as countries such as China develop at a rate that sees them need support from the rest of the world to maintain their development on an ongoing basis.

At the 2006 World Foundry Congress many nations reported that one of their greatest threats was the lack of skilled workers. The problem of an ageing workforce has been debated for many years; with the migration of many workers throughout the world, the ability to fill existing roles has been upheld, but the number of apprentices and graduates has fallen and the problem looks set to remain for the foreseeable future.

The lack of training options, specifically at a vocational level has further added to the demise of the number of people working in the

industry and developing nations have quoted a similar situation.

A recent initiative between industry in India and the VDG in Germany will lead to the creation of a vocational training school designed specifically for the cast metals industry. The initiative has been supported in India by prominant industrialists and the state government, who have provided land and buildings. VDG has provided significant course materials and training content for the courses that will be particularly aimed at supervisors and middle management.

In Europe the OVOTRAIN online virtual vocational training system has been introduced by the Hungarians. An illustrated English-German-Hungarian-Swedish metallurgy expression dictionary is central to the system; this is then translated into Czech, Italian and Polish.

The Foundry Educational Foundation remains the strong link between the industry and the educational establishments in North America, providing top level candidates for the industry and, by use of its ‘foundry in a box’ campaign also brings the world of metal casting to school students.

In other parts of the world, similar

schemes are being launched, such as the casting technology centre being planned for South Africa.

Whilst the automotive industry continues to dominate the cast metals industry’s customer base, new applications are constantly being sought and built upon. Evidence of this is the recent emergence of the wind turbine industry as a €15 billion market that is predicted to double by 2015. Fly anywhere in the world today and look out of the window as you descend and you can’t help but be amazed at the number of wind farms that are springing up.

Clearly sustainable energy is on the world’s political agenda, and much is being done to encourage a greener way of living. So, wind farms look set to be part of our global culture and an opportunity for foundries throughout the world.

In short, yes the industry has changed, yes there is more competition, but there is also a greater need for cast components than ever before. The growth of the global economy and the development of nations has lead to an increased need for cast components that will result in something for everyone. Just look at the statistics.

Established to co-ordinate the organisation of a regular International Foundry Congress, the WFO has since developed into a body involved with numerous activities to satisfy the requirement for the global exchange of information dissemination and international co-operation between Member Associations.

The WFO facilitates the technical co-operation between different nations, internationally united in the same aim - to promote and co-ordinate the activities of the cast metals and associated industries within their own individual countries and overseas.

The objectives of the WFO are as follows:• Promotion of the technology of the cast metals (foundry) industry• Improving the image and understanding of the cast metals industry via the global exchange

of knowledge• Providing focus to all aspects of cast metals engineering• Promoting international co-operation between Member Associations and other organisations• Encouraging education and training in the cast metals industry• Promoting the technical application of research and development of cast components

The World Foundrymen OrganizationNational Metalforming Centre, 47 Birmingham Road,

West Bromwich, West Midlands, B70 6PY, United KingdomTel: +44 (0) 121 601 6976Fax: +44 (0) 1544 340332

Email: [email protected]: www.thewfo.com

See u

s at

GIFA

Stand

No:

10A36


A MODERN CASTING Staff ReportOur world could not have advanced at its rapid rate without the strength, endurance and ingenuity of the metalcaster.

Since the discovery of the earth’s minerals, metalcasting has played an important role in society. An integral part of every technological advance, castings have allowed us to build equipment to feed our people, fight for democracy, build infrastructure and manufacture cars, trains and airplanes. In general, castings have been—and will continue to be—the key ingredient in the recipe for a better way of life.

Metalcasters have long been respected and eminent craftsmen in every community. In many cases, their heroics extended far beyond the utilization of molten metal in creating usable products to advance society. They have been soldiers, statesmen and inventors—and have reshaped North America with a first-class, working labour force that produces goods for the world. In fact, the conception of the US—not to mention the spread of democracy worldwide—was set into motion by seven metalcasters who signed the Declaration of Independence from Great Britain in 1776.

During the wars of medieval times, metalcasters produced cannons. In peace, they recast the metal back into bells. In the Middle Ages, church bells were cast by priests, abbots or bishops who also were trained metal founders. As the metal was melted, the brethren stood around the furnace intoning psalms and prayers. The molten metal was then blessed and divine protection was asked for the bell, which usually bore the name of a saint.

The 20th century saw the explosive refinement of processes and materials used in the foundry for more than 400 years. Vannoccio Biringuccio, the 16th century ‘father of the foundry industry,’ recommended using

the dregs of beer vats and human urine as binders for moulding sand, both of which were in use well into the 20th century.

‘There has been more casting progress since World War II than in the previous 3,000 years,’ wrote Bruce L Simpson in History of the Metalcasting Industry. ‘Still, the demand goes on for foundries to surpass themselves in quantity and quality. Metalcasting remains a basically essential industry, as necessary to space vehicles as it was to mankind’s very first machines. As science is applied more and more, so the skill, education and pay of foundrymen goes up and ever up, increasing in turn the total wealth of the world.’

There is no better example of the true creation of national wealth than the work of the metalcaster. He takes a raw material and through both art and science, creates a product that adds direct value to our society’s ever-progressing way of life.

Beyond the fact that castings are all around us (it is often said one is never more than 10 ft from a casting), metalcasting was ecologically friendly long before it was in vogue. Known as the ‘original recycler,’ the industry gives a new life to as many as 15 million tons of scrap metal each year that would otherwise be rendered useless to society.

From its contributions in providing jobs and employee skills to delivering the dependable, high-quality and cost-effective components necessary to advance technology, metalcasting has impacted virtually every improvement seen by each passing generation. Simply put, our world could not have advanced at its rapid rate without the strength, endurance and ingenuity of the metalcaster.

Following are some of the key technological events that have changed the face of the casting process and its end products.

Timeline ofCasting Technology

With a history set in motion long before the dawn of man, metalcasting is the very cornerstone

of society’s emergence from the Dark Ages and continued prosperity through the 21st century.


B.C.9000 B.C. - Earliest metal objects of wrought native copper are produced in the Near East.3200 B.C. - The oldest casting in existence, a copper frog, is cast in Mesopotamia.3000 B.C. - Early metalcasters cast bronze tools and weapons in permanent stone moulds.3000-2500 B.C. - Small objects are cast via lost wax (investment casting) process in the Near East.1500 B.C. - Wrought iron is discovered in the Near East.600 B.C. - The first cast iron object, a 600-lb. tripod, is cast by the Chinese.233 B.C - Iron plowshares are cast.200 B.C. - Oldest iron castings still in existence produced during the Han Dynasty.

A.D.500 - Cast crucible steel is produced in India.1200s - Loam or sweep moulding is used by European metalcasters to cast bells for cathedrals.1252 - The colossal statue, the Great Buddha at Kamakura, Japan, is cast in high-lead tin bronze. The project began in the 700s and its head alone weighed 140 tons.1313 - The first cannon is cast in bronze by a monk in the city of Ghent.1400s - During the siege of Constantinople, heavy guns are cast from bronze ‘on the spot,’ virtually under the walls of the besieged city… Movable, cast lead type for printing presses revolutionises the world’s methods of communication.1480 - Vannoccio Biringuccio (1480-1539), the first true metalcaster and the ‘father of the metalcasting industry,’ is born. The founder of the Vatican, his De La Pirotechnia is the first written account of proper metalcasting practice.1500s - Sand is introduced as a moulding material in France.

1600s1612 - Mined from under the sea, seacoal is mentioned for the first time by German metalcaster and inventor Simon Sturtevant. 1619 - North America’s first iron furnace is built at Falling Creek, Virginia, on a branch of the James River, 60 miles from Jamestown colony. Three years later, Native Americans destroy it during a raid.1645 - Earliest recorded use of the term ‘foundry’ appears in the Oxford English Dictionary in its variant ‘founderie.’ 1646 - America’s first iron metalcasting facility (and second industrial plant), Saugus Iron Works, near Boston, pours the first American metal casting, the Saugus pot. The Saugus River site was selected by Richard Leader and was built to produce iron products for Massachusetts and England.1661 - First US copper deposits are discovered by Gov Winthrop in Middletown, Conn.

1700s1709 - Two important developments by Abraham Darby from Coalbrookdale, England, improve casting

methods. He developed the first true metalcasting facility flask to modernise moulding practices (which had been carried out in pits on the floor by use of pattern boards tied together or in crude box frames). He would later initiate the use of coke as a furnace fuel for iron production.1722 - A.F. de Reamur, recognised as the world’s first metallurgical chemist, develops malleable iron, known today as European Whiteheart malleable.1750 - Benjamin Huntsman reinvents the cast crucible steel process in England, a process that disappeared after first being developed in India…The English parliament prohibits the refining of pig iron or the casting of iron in the American colonies, contributing to the start of the American Revolution.1756 - Coalbrookdale’s Richard Reynolds oversees the invention of cast iron tram-road rails, replacing wooden rails.1775 - Revolutionary patriot Paul Revere, who operated a bell-and-fittings foundry in Boston, rides from Boston to Lexington warning colonists of the British invasion.1776 - Metalcasters Charles Carroll, James Smith, George Taylor, James Wilson, George Ross, Philip Livingston and Stephen Hopkins sign the American Declaration of Independence.1779 - First iron bridge ever erected (above England’s Severn River) was cast and constructed at Coalbrookdale Works.1794 - John Wilkinson of England invents the first metal-clad cupola furnace, using a steam engine to provide the air blast.1797 - First cast plow in US is invented by Charles Newbold, Sauk, New Jersey.

1800s1809 - Centrifugal casting is developed by AG Eckhardt of Soho, England.1815 - The cupola furnace is introduced to the US (Baltimore).1817 - The first iron water line in the US, 400 ft. long, is laid in Philadelphia.1818 - The first US cast steel is produced by the crucible process at historic Valley Forge Foundry. 1825 - Aluminium, the most abundant metal in the earth’s crust, is isolated from aluminium chloride by Denmark’s Hans Oerstad.1830s - Seth Boyden, Newark, New Jersey, produces US’ first blackheart malleable iron.1832 - Nickel-bronze is produced commercially in England.1837 - The first reliable moulding machine on market is made and used by S. Jarvis Adams Co, Pittsburgh.1847 - Cast steel guns are made by Krupp Works in Germany…Asa Whitney, Philadelphia, obtains a patent on a process for annealing chilled-iron car wheels cast with chilled tread and flange.1847 - John Deere commissions Jones and Quiggs Steel Works, Pittsburgh, to cast and roll a steel plow, which it accomplishes at one-half the product’s previous cost.1849 - A manually operated diecasting machine is patented to supply rapidly cast lead type for newspapers.1850 - Drop-bottom cupola is developed.1863 - Metallography is developed by Henry C Sorby, Sheffield, England, enabling metalcasters to polish, etch and microscopically examine metal surfaces for physical analysis.1867 - James Nasmythe, inventor of the steam hammer, develops a gear-tilted safety ladle to prevent pouring accidents.

Discovery of molten metal (copper beads in fire)

Cast copper frog, 3200 B.C.

Saugus pot, 1642

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1870 - Sandblasting is developed for large castings by RE Tilghman of Philadelphia.1874 - The Colliau cupola, the first commercially made cupola in America, is introduced.1876—The first authenticated aluminium castings were produced by Col William Frishmuth at his Philadelphia foundry. Assembled to produce an engineer’s transit, these castings were made from $1/oz chemically produced aluminium…Manganese-bronze patent is granted to Parsons in England. Tobin Bronze begins developing manganese-bronze in US1880-87 - WW Sly, Cleveland, develops the first casting cleaning mill, greatly reducing hand-chipping and grinding to allow a custom-finished product.1884 - The first architectural application of aluminium, a cast aluminium pyramid that was produced by Frishmuth,

Foundry conveyor, 1890

is mounted on the tip of the Washington Monument.1886 - Charles M Hall, a 22-year-old student at Oberlin College, discovers a process of aluminium reduction through electrolysis. The invention replaced chemical reduction and lowered the metal’s cost (from $15/lb. in 1884 to $0.50/lb. in 1890), spurring a new industry of aluminium applications.1887 - Eli Millett invents a core oven for drying small cores in individual drawers.1890 - The first motor-driven mould conveyor is installed, integrating moulding, pouring and cooling operations.1897 - Iowa dentist BF Philbrook adapts the lost wax investment casting process for producing dental inlays, the process’ first non-art application of the modern metalcasting age.1898 - Poulson and Hargraves (UK) produce the first sand moulds bonded with sodium silicate… Germany’s Imperial Navy recommends copper-nickel alloys containing 4-45% Ni for salt-water piping system.1899 - Electric arc furnace, developed by France’s Paul Heroult, begins commercial production.

1900s1900 - Brinnell hardness test machines introduced…Aluminium-bronze in regular production in the USEarly 1900s - First patent

Early iron foundrySigners of Declaration of Independence, 1776


for low-pressure permanent mould casting process issued to England’s EH Lake.1901 - American Steel Foundries (St. Louis) produces the first centrifugal cast rail wheels.1903 - The Wright Brothers’ first successful machine-powered aircraft contains a cast aluminium block and crankcase (together weighing 152 lbs), produced either at Miami Brass Foundry or the Buckeye Iron and Brass Works. 1905 - HH Doehler patents the diecasting machine.1906 - The first electric arc furnace is installed in US at Halcomb Steel Co, Syracuse, New York… First low-frequency induction furnace is installed at Henry Diston & Sons, Tacony, Pa.1907 - Alfred Wilm discovers that the properties of cast aluminium alloys can be enhanced through heat treating and artificial aging.1908 - Stockham Homogenous Sand Mixer Co, Piqua and Newark, Ohio, releases the sand cutter.

1910s1910 - Matchplates are developed, fostering the viability of jolt-squeeze machines.1911 - Metallurgical microscope is obtainable…First electric arc furnace for metalcasting is installed at Treadwell Engineering Co, Easton, Pennsylvania.1912 - The first muller with individually mounted revolving mullers of varying weights is marketed by Peter L. Simpson…Sand slinger invented by EO Beardsley & WF Piper, Oregon Works.1915 - Experimentation begins with bentonite, a colloidal clay of unusually high green and dry strength…Ajax Metal Co, Philadelphia, installs first low-frequency induction furnace for nonferrous melting.1916 - Dr Edwin Northrup, Princeton Univ, invents the coreless induction furnace. 1917 - Alcoa completes a great deal of early development work in aluminium as World War I generates great demand for high-integrity castings for aircraft engines.1918 - The first fully automated metalcasting facility in Rockford, Illinois, casts hand grenade hulks for the US Army.

1920s1921 - Modification of the silicon structure in aluminium begins as Pacz discovers that adding metallic sodium to molten aluminium just prior to pouring greatly improves ductility… Copper-silicon alloys are prepared in Germany as a substitute for tin bronzes.1924 - Henry Ford sets a ‘production record’ of 1 million autos in 132 working days. Automotive manufacturing will grow to consume one-third of casting demand in the US1925 - X-ray radiography is established as a tool for checking casting quality. By 1940, all military aircraft castings require x-ray inspection prior to acceptance…American Brass, Waterbury, Conn, installs first medium-frequency induction furnace in the US1928 - Alcoa develops the first aluminium vehicle wheel,

a sand-cast 355 alloy designed for truck trailers.

1930s1930 - First high-frequency coreless electric induction furnace is installed at Lebanon Steel Foundry, Lebanon, Pa… Spectrography is pioneered by Univ of Michigan professors for metal analysis… Davenport and Bain develop the

austempering process for iron castings.1937 - ARL founder Maurice Hasler produces the first grating spectrograph for the Geological Survey of California. Spectrometers begin finding their way into foundries by the late 1940s, replacing the previous practice of metallurgists estimating chemical compositions with a spectroscope and welder’s arc…The austempered microstructure in cast iron is recognized.

1940s1940 - Chvorinov develops the relationship between solidification time and casting geometry.Early 1940s - Statistical process control is first employed as a quality control tool in US machine shops, principally to control dimensional tolerances…Inoculation of grey iron becomes common, as high-quality cast irons replace scarce steel.1941 - US Lt Col WC Bliss tells the AFA St. Louis Chapter that ‘the side which maintains the larger production of war goods is going to win the war.’ The War Production Board reports later that each US soldier requires 4,900 lbs., of steel compared to 90 lbs. in World War I.1942 - The use of synthetic sands increases as a replacement for many war materials.1943 - Keith Millis, a 28-year-old metallurgist working at INCO searching for a replacement to chrome due to interrupted supply, discovers that magnesium alloy in molten iron produces a spheroidal graphite structure. In 1949, he, Albert Gagnebin and Norman Pilling would receive a US patent on ductile iron production via magnesium treatment.1944 - The first heat-reactive, chemically cured binder is developed by Germany’s Johannes Croning to rapidly produce mortar and artillery shells for Axis troops during World War II. Two years after the war, his shell process is discovered among other inventions in the German patent office and made public. Croning is recognised with an AFS Gold Medal in 1957 for his invention.1946 - Allied investigators uncover German foundry research on high-temperature alloys…Having ‘heard’ of the Croning discovery (prior to the release of the report), Ford’s Ed Ensign and EI Valyi, Navy Bureau of Ships, attempted to replicate the process and produced shell-moulded castings at Midwest Foundry, Coldwater, Michigan.Late 1940s - Thermal sand reclamation is applied to core sands and, to a limited degree, clay-bonded sands.1948 - The first non-labouratory ductile iron casting is produced at Jamestown Malleable Iron Co, Jamestown, New York, as a 66-in. test bar is poured…Industry’s first ductile iron pipe is cast at Lynchburg Foundry, Lynchburg, Va.1949 - Keel blocks, diesel engine parts, a pressure cylinder, an 8-in. cube and two cylinder liners become ductile iron’s first commercial castings at Cooper-Bessemer, Grove City, Pennsylvania…Development of magnesium-ferrosilicon makes ductile iron treatment far easier…Buffalo Pipe & Foundry Co, Tonawanda, New York, is the first US operation to pour castings using Croning’s shell process.

1950sEarly 1950s - Experimentation in high-pressure moulding begins, as metalcasters begin to increase the air pressure in air squeeze moulding machines to increase mould hardness (density)…Fast-drying core oils are introduced…The pneumatic scrubber is developed to reclaim clay-bonded sands. Several wet reclamation systems also are in operation.1951 - Ford Motor Co, Dearborn, Michigan, converts 100% of its crankshaft production to ductile iron.1952 - D Process is developed for making shell moulds with fine sand and fast dry oil by Harry Dietert…Sodium-silicate/CO

2 system is introduced.

1953 - Hotbox system of making and curing cores in one Lost Foam Pattern, 1950s


operation is developed, eliminating the need for dielectric drying ovens.1954 - The CO

2 process, a novel mould and coremaking

process, is introduced from Germany…Working closely with General Motors, B&P develops a method for coating individual sand particles with resin binder. It also introduces a coreblower capable of producing cores with resin-coated shell sand - a modification to the Croning process.1955 - Ductile iron pipe is introduced to the marketplace by People’s Gas of Chicago, the first to install ductile iron gas mains.Mid-1950s - The squeeze casting process originates in Russia.1956 - The first Betatron is installed in US foundry at ESCO Corp, Portland, Oregon, for radiography of heavy steel castings.1957 - The vertically parted flaskless green sand moulding production machine is invented by Vagn Aage Jeppesen, a 40-year-old professor at the Technical Univ. of Denmark. He was granted a patent in 1959, which was purchased by Dansk Industri Syndikat in 1961. 1958 - Harold F Shroyer obtains a patent for the full mould process, a process developed by artists in which simple patterns and gating systems are carved from expanded polystyrene and placed into a green sand mould. The process, known today as lost foam casting (using loose, unbonded sand), is patented a short time later…Phenolic and furan acid-catalysed nobake binder systems are introduced…Ductile iron desulfurisation via shaking ladles is developed in Sweden.1959 - General Electric utilises the Transient Heat Transfer digital computer program and successfully applies the finite difference method to heavy steel casting production.

1960s1960 - Furan hotbox binders are developed for core

production…Deep bed filters are used commercially for aluminium casting at Alcoa and British Aluminium in UK…Compactibility and methylene blue clay tests are developed for green sand control.1961 - Alcohol-borne shell coating process is introduced (warm-coated).1962 - New CO

2 sand testing method is introduced

for sands bonded with sodium silicate and cured with CO

2…Beardsley & Piper’s Al Hunter, Bob Lund and

Angello Bisinello develop the first automated green sand moulding machine. In their design, the cope and drag are side-blown simultaneously and then hydraulically squeezed. The birth of automated matchplate moulding reportedly improved metalcasting productivity by levels as much as 60% in a short amount of time…Phenolic hotbox binders introduced.1963 - Shell flake resin is introduced, eliminating the need for solvents.1964 - Dell & Christ’s paper on mould inoculation spurs the development of many of today’s forms of mould and late stream inoculation…The first vertically parted green sand machine (max. 240 moulds/hr.) is delivered to United Danish Iron Foundries in Frederiksvaerk, Denmark. Early adopters report man-hour per ton improvements on the order of 50%.1965 - Oil urethane nobake binder systems are used for cores and moulds…General Electric’s Jim Henzel and Jack Keverian predict freezing patterns in large steel castings via computer…Cast metal matrix composites are first poured at International Nickel Co, Sterling Forest, New York.1968 - The coldbox process is introduced by Larry Toriello and Janis Robins and introduced to the metalcasting industry by Ashland Chemical Co for high-production coremaking. Germany’s Daimler-Benz foundry in Mannheim is the first to run the process for automotive parts. John Deere Silvas Foundry, Moline, Illinois, is the first to use the process for mass-production in North America.1969 - The Chevrolet Vega is introduced by General Motors, featuring the first all-aluminium block with no cast iron cylinder liners. A total of 2.5 million blocks were produced during the vehicle’s life cycle.Late-1960s - Scanning electron microscope (SEM) is invented in England…Thermal analysis begins to be used in iron foundries for the rapid determination of carbon equivalent and phosphorous contents, making it possible to study the transformation of an alloy during cooling…Manganese Bronze & Brass Co and J Stone & Co join to promote nickel-aluminium bronze propellers.

1970s1970 - The sodium-silicate/ester catalysed nobake binder system is introduced for cores and moulds…Safety-critical ductile iron steering knuckles are introduced on Chevrolet’s Cadillac…A new phenolic urethane nobake process is introduced by Ashland Chemical, replacing oil sand dump box operations and significantly reducing energy requirements for core/mould production throughout the 1970s…Diran Apelian’s doctoral work at the Massachusetts Institute of Technology (MIT) leads to the development of foam filters for metalcasting by Olin Metals. Commercial ceramic foam filters will be in use in metalcasting facilities by 1974.1971 - The vacuum-forming or V-Process moulding

Shell Core Machine, 1950s

Prototype Vertically Parted Green Sand Mould Machine 1959

Matchplate Moulding Machine 1960s


method of using unbonded sand with a vacuum is developed in Japan…MIT doctoral candidate David Spencer performs experiments leading to semi-solid moulding (SSM), a process in which a partially frozen metal (fluidity similar to machine oil) can be poured into a die cavity. Following advancement in metal slurry consistencies with Professor Mert Flemings, Newton Diecasting Co, New Haven, Conneticut, produces the first semi-solid castings.1972 - A 1-lb crankshaft for a refrigerator compressor produced at Wagner Castings (designed and engineered by Tecumseh) becomes the first production-volume austempered ductile iron (ADI) component. Wagner also produces the first as-cast ductile iron ductile rods for passenger cars… CANMET uses real-time radiography to study the flow of steel in moulds… Hitchiner Manufacturing, Milford, NH, patents counter-gravity (vacuum) casting process.1973 - The first US foundry argon oxygen decarburisation (AOD) unit is installed at ESCO Corp.1974 - Fiat introduces the in-mould process for ductile iron treatment… The phenolic urethane nobake binder system is introduced for mould production.Mid-1970s - Alcoa and Union Carbide commence rotary degassing for wrought aluminium. Reading Foundry Products would apply this technology to aluminium foundries in the mid-1980s...Digital codes are developed to simulate solidification and fluid flow analysis…Ultrasonic verification of ductile iron nodularity is developed…Metalcasting facilities examine new beneficial reuse routes for spent foundry sand, leading to applications such as cement and paving products, bricks and flowable fill.1976 - Foote Mineral Co and BCIRA (UK) develop compacted graphite iron…Acid-slag cupola practices plus external desulfurisation with CaC

2 begin to replace basic

slag cupolas.1977 - General Motors installs ADI rear differential sets in passenger cars…The alumina phosphate nobake binder system, an inorganic nonsilicate binder, is introduced for mould production.1978 - The furan/SO

2 binder system is developed for core

and mould making…Polyurethane nobake binder system is introduced for aluminium applications.

1980sEarly 1980s - Tundish ladle is embraced by industry as favored practice of nodularizing ductile iron…3-D relational parameters are developed for CAD solid models.1981 - High-production lost foam casting begins at General Motors’ Massena, New York, plant for aluminium cylinder heads.1982 - Warmbox binder system is introduced.1983 - Air impulse moulding process is developed…Free radical cure/SO

2 binder system is introduced.

1984 - Charles Hull applies for a patent on stereolithography process. Other rapid prototyping techniques emerge shortly after…Phenolic ester nobake binder is introduced…Thermal analysis

makes breakthrough in molten aluminium processing for determination of grain refinement and silicon modification.1985 - Phenolic ester coldbox binder is developed…New automaker Saturn makes a strategic decision to select lost foam process for its aluminium cylinder blocks and heads and ductile iron crankshafts and differential cases. Mid-1980s - Computer solidification software is commercialized…Amine recycling is introduced to enhance the environmental benefits of the amine-cured coldbox process…Ube Machinery introduces first squeeze casting equipment...Aikoh’s (Japan) flux injection technology is initiated into US aluminium foundry market.Late 1980s - 3-D visualisation techniques are developed…CaO/CaF2 desulfurisation of cupola-melted ductile base iron begins to replace CaC2 method…Lanxide, Newark, Delaware, develops pressureless metal infiltration process for particulate-reinforced metal bodies…Magnesium wire injection method for ductile iron treatment is first tested…Casting solidification modeling software gains acceptance, allowing metalcasting facilities to optimize quality, production and cost prior to actually pouring a casting.1988 - Rapid prototyping and CAD/CAM technologies combine in a breakthrough to shorten tooling development time…Ford adapts Cosworth process precision sand casting process for high production...Metaullics Systems combines flux injection/rotary degassing technologies for aluminium processing.1989 - IMI (Yorkshire, UK) begins experimenting with bismuth as a lead substitute in copper alloys.

1990s1990 - Equipment for semi-solid casting is introduced by Alumax Engineered Materials and Buhler, Inc…Foseco patents a direct-pour system that permits casting production without conventional gating/risering. Major automotive application comes in 1995 with CMI International’s upper intake manifold…Precision sand casting and casting quality for engine blocks are improved in mass production by major automotive companies with the Cosworth and Zeus processes for aluminium and the Loramendi Key Core process for precision sand cast iron applications.1991 - ‘Dry ice’ CO

2 process is developed for cleaning

coreboxes and foundry tooling…A noncontact gauge for accurate dimensional analysis of lost foam patterns and sand cores is developed through the AFS Lost Foam Consortium. Eight years later, the consortium develops an instrument to measure the gas permeability of lost foam pattern coatings (which controls flow of metal and has a dominant effect on casting quality).1993 - First foundry application of a plasma ladle refiner (melting and refining in one vessel) occurs at Maynard Steel Casting Co, Milwaukee.1994 - Use of low-expansion synthetic mullite sand for lost foam is patented by Brunswick Corp, Lake Forest, Illinois, to enable precision casting of large components…Delphi Chassis Systems and Casting Technology Co begin a program on squeeze-cast aluminium front knuckle, the first high-volume production (1.5 million cars) two-cavity squeeze-cast aluminium conversion of its kind.Mid-1990s - Microstructure simulation is developed, contributing to better understanding of metallurgy effects and the prediction and control of mechanical properties in castings…Semi-solid casting makes commercial inroads and market penetration.1996 - Cast metal matrix composites (brake rotors) are used for the first time in production model automobiles, the Lotus Elise… Environmentally friendly (fluorine-free) fluxes are developed at the Worcester Polytechnic Institute and commercialised… General Motors Corp introduces GMBond, a water-soluble biopolymer-based core sand binder that is nontoxic and recyclable.

SSM billet, 1971GMBond-produced engine block, 1996


1997 - AFS Consortium research at CANMET, Ottawa, Canada, results in the development and commercialisation of lead-free copper alloys using bismuth and selenium…Following tests at Germany’s Aachen Univ, American Cast Iron Pipe Co, Birmingham, Alabama, builds a continuously operated electric arc furnace for cast iron production.Late 1990s - Stress and distortion simulation introduces the benefits of controlling casting distortion, reducing residual stresses, eliminating hot tears and cracking, minimising mould distortion and increasing mould life.

2000s2001 - NASA and the Dept. of Energy/OIT released physics-based software tool to accurately predict the filling of expanded polystyrene patterns and sand cores as numerous variables are changed…Mercury Marine installs North America’s first pressurized lost foam casting line at its new facility in Fond du Lac, Wisconsin.2002 - Math-based modeling is used to develop a new sand core blowing simulation capability for process modeling software. 2003 - The AFS Magnesium Div completes a research project proving that magnesium could be cast via the lost foam casting process. Similar trials confirmed the castability of magnesium via the V-Process.

Comments on the timeline should be directed to [email protected]

SourcesC.F. Walton, T.J. Opar, Iron Castings Handbook, Iron Castings Society, Inc., (1981). • J. Gerin Sylvia, Cast Metals Technology, AFS, (1990). • E.L. Kotzin, Metalcasting & Moulding Processes, AFS (1981). • J.P. LaRue, Basic

Metalcasting, AFS (1989). • C.A. Sanders and D.C. Gould, History Cast in Metal, AFS, (1976). • Proceedings of 1992 Coreless Induction Melting Conference, AFS, (1992). • B.L. Simpson, History of the Metalcasting Industry, AFS (1948). • J.A. Gitzen, Progress in the Development and Utilization of Additives in the Foundry Industry, AFS (1957). • 1995 Lost Foam Technology and Applications Conference Proceedings, AFS (1995). • Aluminium: Design and Application (Vol. II), ASM, (1967). • High-Pressure Moulding, 2nd Edition, AFS (1987). • Foundry Trade Journal (Sept. 11, 1986). • Metals Handbook, Ninth Edition, Vol. 15 Casting, ASM International (1988). • 1991 AFS International Sand Reclamation Conference, AFS (1991) • AFS/CMI Conference on Green Sand Technology—Productivity for the ‘80s, AFS (1983). • ADI: The New Benchmark Material video, Applied Process, Inc. • ‘1997 Hoyt Memorial Lecture: Lost Wax to Lost Foam: Reflections on the Past, Present and Future,’ E.L. Kotzin, July 1997 MODERN CASTING, p. 42-45. • 1999 Charles Edgar Hoyt Memorial Lecture: ‘From a Monument to the Vega: The Journey of the Aluminium Casting Industry,’ J.R. Bodine, May 1999 MODERN CASTING, p. 60-63. • A Tribute to Keith Millis and the Unveiling of Ductile Iron 50 Years Ago,’ October 1998 MODERN CASTING • MODERN CASTING’s A Look Back at the 20th Century Series (2000-2001). • Special thanks to Bill Henning, Miller & Co. (retired); Diran Apelian, Worcester Polytechnic Institute; Paul Carey and Jim Archibald, Ashland Specialty Chemical Co.; Stubbs Davis, Durametal Corp.; Raymond Donahue, Mercury Marine Div.; Matt Granlund, Foundry Systems Control; Roy Lobenhofer, Lobenhofer Consulting, Inc.; Norris Luther, Luther & Assoc.; Mahi Sahoo, CANMET; Geary Smith, Manufacturers’ Brass & Aluminium; Bob Voigt, Penn State Univ.; David Neff, Metaullics Systems, LLC; and Norm Bliss, Ian Kay, Wayne Rasmussen, Steve Robison and Joe Santner, AFS/CMI.

Tuesday, June 12, 200712-16 June 2007 Metec 2007 – Strong Innovation Power of the Metallurgy Industry PrevailsVenue: Dusseldorf Exhibition Grounds Tel: +49 211 4560 01E Mail: [email protected] Website: www.messe-duesseldorf.de

Tuesday, June 12, 200712-16 June 2007 GIFA (inc WFO Technical Forum) METEC, Germany THERMPROCESS, NEWCASTVenue: Dusseldorf Exhibition Grounds, Tel: +49 211 4560 01E Mail: [email protected] Website: www.gifa.de

Sunday, July 15, 200715-21 July 2007 15th Annual International Conference on Composites/Nano Engineering, ICCE-15Venue: Hong Kong, China Website: http://myweb.polyu.edu.hk

Tuesday, August 28, 200728-30 August 2007 Aluminium China 2007Venue: Shanghai New international Expo Centre Tel: + 0086 10 85189070 207 – Contact Yog Wang E Mail: [email protected]: www.reedexpo.com

Tuesday, September 11, 200711-14 September 2007 The International Fair of Mining, Metallurgy and Power Industries SILMEX 2007Venue: The City of Sosnowiec, 124 Braci Mieroszewskich Street, Poland Website: www.silmex.pl

Wednesday, September 12, 200712-13 September 2007 Materialise Innovation ForumVenue: Leuven, Beligium Website: www.materialise.com

Sunday, September 16, 200716-19 September 2007 AFS Foundry Executive Conference Wentworth by the Sea, New Castle, NH

Monday, September 24, 200724-29 September 2007 3rd International Conference on Advanced

Research in Virtual and Rapid Prototyping(VRAP 2007) Venue: Leiria, PortugalWebsite: www.dem.estg.ipleiria.pt/vrap2007

Wednesday, September 26, 200726-28 September 2007 13th International Fair of Technologies for Foundry 6th Exhibition of Technology, Processing and Application of Non-ferrous Metals. Venue: Kielce, Poland Website: www.metal.targikielce.pl orwww.nonfermet.targikielce.pl or www.targikielce.pl

Thursday, October 4, 20074-10 October 2007 Non-Ferrous Founders Society (NFFS), Annual Meeting The Wigwam Resort, Phoenix, Arizona

Sunday, October 7, 20077-10 October 2007 AFS 19th EHS Conference Sheraton Music City Hotel, Nashville, Tennesse

Tuesday, October 9, 20079-11 October 2007 European Symposium on Pressure Equipment (ESOPE) 2007Venue: Palais Des Congres, Paris, France Tel: + 33 (0) 1 47 17 62 73 Email: [email protected] Website: www.afiap.org

Sunday, October 14, 200714-17 October 2007 Investment Casting Institute (ICI), 55th Annual Technical Conference & ExpoVenue: Renaissance Cleveland Hotel, Cleveland, OhioTel: + 201/573-9770

Wednesday, October 17, 200717-19 October 2007 AFS Labor Relations & Human Resource Conference Sandpearl Resort, Clearwater, Florida

Thursday, October 18, 200718-20 October 2007 METAL-FORUM of UKRAINE 2007Conference & Specialized Exhibition Venue: KyivExpoPlaza, Kiev, Ukraine Tel: +49 2166 610387 E Mail: [email protected]: www.metal-forum.org

CALENDAR OF EVENTS

Sunday, October 21, 200721-23 October 2007 AFS Midwest Regional Conference Grand Wayne Center, Fort Wayne, Indiana

Wednesday, October 24, 200724-28 October 2007 Korea Metal Week 2007Venue: Korea International Exhibition Centre (Kintex) Tel: + 82 2 780 4411 (103) Email: [email protected]: www.koreametal.or.kr or www.ktfairs.com

Tuesday, November 6, 200706-08 November 2007 Euopean Trade Fair & Forum for composites, Technology and ApplicationsVenue: New Stuttgart Trade Fair Centre Tel: +49 (0) 211 90191 -128 - Contact Dr Mike Seidensticker Email: [email protected] Website: www.composites-europe.com

Tuesday, November 13, 200713-14 November 2007 AFS Advanced Foundry Environmental Seminar Location to be determined

Wednesday, November 14, 200714-15 November 2007 Casting Industry Suppliers Association (CISA), Fall Business Meeting. Double Tree, Rosemont, Illinois

Thursday, November 22, 200722-23 November 2007 3° COLFUN 07Venue: Centro Cultural Universitario de Tandil, ArgentinaEmail: [email protected] Website: www.colfun-07.org.ar

Wednesday, December 12, 200712-15 December 2007 Steel Founders' Society of America (SFSA), 61st Technical & Operating Conference The Drake Hotel, Chicago, Illinois

Friday, February 1, 200868th World Foundry CongressChennai, India. Website: www.wfcindia08.com

Thursday, February 7, 20087-10 February 2008 Cast for Competitive edge 68th World Foundry

Congress, to be held concurrently with 56th Indian Foundry CongressVenue: Chennai Trade Centre in Chennai Tel: +91 44 2374 2394Email: [email protected] Website: www.wfcindia08.com

Thursday, March 6, 20086-7 March 2008 3rd International Cupola ConferenceVenue: Reims Conference Centre, France Tel: + 33 (0) 141 146300Email: [email protected] Website: www.ctif.com

Thursday, March 13, 200813-15 March 2008AFS Northwest Regional Conference Hilton Portland & Executive Tower Hotel, Portland, Oregon

Saturday, May 17, 200817-20 May 2008 CastExpo 2008 Georgia World Congress Center, Atlanta, GeorgiaWebsite: www.afsinc.org

Wednesday, June 4, 20084-6 June 2008 6th European Conference on continuous Casting 2008Venue: Riccione, Italy Tel: 00 39 0276021132 or 0276397770Website www.aimnet.it/eccc2008.htm

Tuesday, September 23, 200823-25 September 2008 Aluminium Germany 2006 Post Show ReportVenue: Essen Exhibition Centre, Germany Tel: 020 8910 7741Email: [email protected] Website: www.aluminium-messe.com

Sunday, October 12, 200812-15 October 2008 Non-Ferrous Founders' Society (NFFS), Annual Meeting. Coeur d'Alene Resort, Coeur d'Alene, Indiana

Sunday, October 19, 200819-22 October 2008 12th World Conference on Investment CastingVenue: Adams Mark Hotel, Dallas, TXWebsite: www.investmentcasting.org

Thursday, October 23, 200823-25 October 2008 AFS International Lost Foam Casting Conference. Location to be determined

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