Shipments to rebound 3% in '02, begin healthy expansion. (AFS 2002 Metalcasting Forecast & Trends).The drastic decline in shipments of metal castings Metal casting A metal-forming process whereby molten metal is poured into a cavity or mold and, when cooled, solidifies and takes on the characteristic shape of the mold. that began in late 2000 continued throughout '01, resulting in a final shipment total of 13,074,000 tons, the industry's lowest total since 1993. While the accelerated downturn caused by the terrorist attacks is expected to continue into '02, an economic expansion is expected at mid-year. As a result, final casting tallies TALLIES, evidence. The parts of a piece of wood out in two, which persons use to denote the quantity of goods supplied by one to the other. Poth. Obl. pt. 4, c. 1, art. 2, Sec. 7. in '02 should post a 3% gain to 13.45 million tons. Continued interviews with econometric e·con·o·met·rics n. (used with a sing. verb) Application of mathematical and statistical techniques to economics in the study of problems, the analysis of data, and the development and testing of theories and models. forecasters and buyers of castings support the call for an expansion in '02. According to according to prep. 1. As stated or indicated by; on the authority of: according to historians. 2. In keeping with: according to instructions. 3. casting users, changes in casting demand in specific market sectors will be dictated dic·tate v. dic·tat·ed, dic·tat·ing, dic·tates v.tr. 1. To say or read aloud to be recorded or written by another: dictate a letter. 2. a. by worldwide conditions and changes in technology. The predicted peak spending years of Baby Boomers See generation X. and immigrant populations in the U.S. are expected to drive the economy in the next 5 years to reach boom proportions in specific market sectors. Major Influences on Casting Demand The production of light vehicles fell to a 10-year low in '01, Production is expected to rise 5% in '02 and continue to expand another 10% in '03 before returning to '99 peak levels by '04. Though passenger car production is expected to rebound rebound (rē´bownd), n/v 1. a recovery from illness. n 2. an outbreak of fresh reflex activity after withdrawal of a stimulus rebound adjective and grow as a percentage of total vehicles, light trucks also are predicted to remain strong. Based on '02 levels, a long-term growth of 2 million vehicles in light vehicle production in the U.S. is forecast. Medium-to-heavy truck production, which declined to a nine-year low in '01, is forecast to begin a slow climb back to 350,000-unit levels and again reach peak production by '05. Railroad railroad or railway, form of transportation most commonly consisting of steel rails, called tracks, on which freight cars, passenger cars, and other rolling stock are drawn by one locomotive or more. freight car shipments dropped from their highs in '98-99 to a 20-year low in '01. An increase in deliveries to 40,000-car levels is expected in '02, followed by a further gain in '03. Imports of castings from throughout the world will continue to affect shipments of castings from U.S. foundries, despite increases in overall demand. Weak currency exchange rates and low labor rates in many countries are predicted to affect shipments, as well as cause depressed pricing conditions. Due to September's terrorist attacks and their worldwide economic impact, this year's forecast was reconfigured in October '01. Following is the short- and long-term (looking ahead 10 years from last year's base level) for end-use segments within each of the major cast metal groups. Gray Iron Just a few years after five consecutive years above the 6-million-ton mark in the mid-'90s, gray iron shipments are forecast to drop below 5 million tons in 02 and Continue to decline at an annual rate of 0.1% in the next 10 years. A minimal gain is forecast for '03 and subsequent years, but substitution of other materials and increases in imports will hurt shipments from U.S. casting suppliers. Light Vehicles--The use of gray iron in light vehicles has dropped 700,000 tons from its 2-million-ton high in '97 and is expected to decline another 10% in '02 to 1,176,000 tons as conversion of applications to aluminum accelerates, Shipments to the automotive industry The automotive industry is the industry involved in the design, development, manufacture, marketing, and sale of motor vehicles. In 2006, more than 69 million motor vehicles, including cars and commercial vehicles were produced worldwide. are expected to decline at an annual rate of 2.2% to 1.06 million tons in '11. The weight of gray iron castings per light vehicle is forecast to decrease from a high of 650 lb/vehicle in '81 to 180 lb in '11. The large increase in the sale of light trucks from 18% of the total light vehicles in the early '80s to 55% in '99 has softened soft·en v. soft·ened, soft·en·ing, soft·ens v.tr. 1. To make soft or softer. 2. To undermine or reduce the strength, morale, or resistance of. 3. the blow to gray iron and reduced the rate of decline and lengthened length·en tr. & intr.v. length·ened, length·en·ing, length·ens To make or become longer. length  en·er n. the life of the iron block and head foundry A semiconductor manufacturer that makes chips for third parties. It may be a large chip maker that sells its excess manufacturing capacity or one that makes chips exclusively for other companies. . It is forecast,
however, that current and future Glean Air Act legislation and
regulations will accelerate the need for lighter cars and light trucks,
and reduce iron casting usage.Medium-to-Heavy Trucks--After truck and trailer production dropped 30% to a 10-year low in '01, production is expected to increase 15-20% in '02. Gray iron casting shipments are expected to improve by nearly 20% in '02 to 190,000 tons, followed by a similar increase in '03. Brake castings should return to peak levels again in '04 and '05. Municipal--Imports, primarily from India, comprise 32% of all shipments of municipal castings. Based on expected increases in housing starts in '02, municipal casting shipments are expected to increase 2% this year to 494,000 tons and 1.1% annually. Soil Pipe--Gray iron soil pipe is forecast to fall 3% to 248,000 tons in '02, Over the next 10 years, the Years, The the seven decades of Eleanor Pargiter’s life. [Br. Lit.: Benét, 1109] See : Time decline is expected to continue to 180,000 tons. Ingot ingot Mass of metal cast into a size and shape such as a bar, plate, or sheet convenient to store, transport, and work into a semifinished or finished product. The term also refers to a mold in which metal is so cast. Molds--Gray iron ingot mold a box or mold in which ingots are cast. See also: Ingot and stool stool (stldbomacl) feces. rice-water stools the watery diarrhea of cholera. silver stool castings are declining 5.9% per year. Shipments in the U.S. are estimated at 46,000 tons from three main producers. Imports from Brazil have increased to 19,000 tons/year, or 40% of shipments. Sanitary sanitary /san·i·tary/ (san´i-tar?e) promoting or pertaining to health. san·i·tar·y adj. 1. Of or relating to health. 2. & Radiator--Despite an expected increase in housing starts this year, gray iron shipments are forecast to decline another 5% in '02 to 280,000 tons as conversions to plastics continue. A 4.3% long-term annual rate of decline is forecast. Valves & Fittings--A 1.8% increase in casting shipments is forecast for '02 to 275,000 tons. Imports of valve and fitting castings are expected to grow to represent 42% of all shipments in '02. Greater demand for energy-related industries and an increase in exports should cause a 1% long-term growth rate. Internal Combustion combustion, rapid chemical reaction of two or more substances with a characteristic liberation of heat and light; it is commonly called burning. The burning of a fuel (e.g., wood, coal, oil, or natural gas) in air is a familiar example of combustion. Engines--With 58% of the diesel engine demand in the U.S. consumed in trucks and buses, this sector has suffered from the decline in truck production. About 470,000 tons of gray iron casting shipments are expected to be consumed by this sector in '02, which represents an increase of 7% over last year's poor showing, Imported castings (primarily Brazil, Mexico and Europe) are estimated at 185,000 tons, or 39% of U.S. shipments in this sector. A 10-year, 2.3% annual growth rate is expected as production of truck, construction and farm vehicle shipments increase. Farm Machinery & Equipment--The consumption of gray iron castings in farm equipment is forecast to rise 5.6% in '02 to 303,000 tons, based on expected increases in production of farm machinery, including tractors. Farm equipment manufacturing is expected to grow to peak levels in the next five years. Construction Machinery & Equipment--Gray iron casting shipments to this sector declined 5% last year to 227,000 tons after six years of growth. An increase of 4% in casting shipments to 237,000 tons is expected in '02. Over the long-term, annual growth of 1.8% is expected. Mining & Oil Field Equipment--Shipments of gray iron castings increased 12% last year as mining and oil field equipment manufacturers continued strong, despite the downturn in the economy. Oil field equipment production rose 15% in '01 and is expected to rise another 5% in '02. Mine production increased again last year at a rate of 12% and is expected to rise 3% in '02. Machine Tools--The domestic machine tool industry dropped to its lowest levels in 10 years, with '01 production expected to finish 30% below '00. Gray iron casting shipments for metalworking machinery declined 9.4% to 86,000 tons and dropped as much as 50% in some categories. Casting orders are expected to increase slightly this year to 90,000-ton levels but won't increase significantly until late in the year. Special Industry Machinery--Most categories of special machinery--including textile, printing, packaging and paper machinery--declined last year, causing the falloff fall·off n. A reduction or decrease: a falloff in car sales. Noun 1. falloff - a noticeable deterioration in performance or quality; "the team went into a slump"; "a gradual slack in in casting shipments to these sectors to range from 3-10%. In '02, a 4% overall rebound (to 207,000 tons) is expected as well as a 1.5% annual growth rate over the next 10 years. Pumps and Compressors--Gray iron shipments are forecast to grow 1-2% in '02 from last year's low of 258,000 tons. Refrigeration refrigeration, process for drawing heat from substances to lower their temperature, often for purposes of preservation. Refrigeration in its modern, portable form also depends on insulating materials that are thin yet effective. & Air Conditioning--Gray iron casting usage in compressors and other parts used in refrigeration, heating and air conditioning air conditioning, mechanical process for controlling the humidity, temperature, cleanliness, and circulation of air in buildings and rooms. Indoor air is conditioned and regulated to maintain the temperature-humidity ratio that is most comfortable and healthful. equipment fell 7% from '99 levels to 143,000 tons. Declines were even higher--near 20%--in medium-sized compressor compressor, machine that decreases the volume of air or other gas by the application of pressure. Compressor types range from the simple hand pump and the piston-equipped compressor used to inflate tires to machines that use a rotating, bladed element to achieve castings, according to last quarter reports. An upturn at mid-year is expected to bring shipments up 2%. Electric Motor--After posting a 10% loss in '01, shipments should increase 3% in '02 to 56,000 tons. This market is expected to decline 1.8% annually due to conversions to lighter metals and increases in imports. Household Appliances--After falling 11% in '01, the consumption of gray iron castings is forecast to fall another 16% in '02 and 7.6% annually due to continued substitution by aluminum and plastics. Imports--Imports of gray iron castings increased to more than 1 million tons and are now estimated at 20% of U.S. shipments. About 244,000 tons of gray iron castings for light vehicles are imported, primarily from China, Mexico and Canada. A domestic shortage of diesel engine castings exists in the U.S. with about 39% of shipments imported, primarily from Brazil, Germany and Mexico. India dominates the import tonnage TONNAGE, mar. law. The capacity of a ship or vessel. 2. The act of congress of March 2, 1799, s. 64, 1 Story's L. U. S. 630, directs that to ascertain the tonnage of any ship or vessel, the surveyor, &c. used in municipal castings, while Asian nations Noun 1. Asian nation - any one of the nations occupying the Asian continent Asian country country, land, state - the territory occupied by a nation; "he returned to the land of his birth"; "he visited several European countries" are the major suppliers of valve and fittings. Ductile Iron Ductile iron, also called ductile cast iron or nodular cast iron, is a type of cast iron invented in 1943 by Keith Millis[1]. While most varieties of cast iron are brittle, ductile iron is much more ductile, as the name implies. Ductile iron casting shipments in the U.S. are forecast to increase 4% to 4 million tons in '02 and grow annually at 2.3% over the next 10 years. Ductile iron sales are forecast to grow to $5.1 billion in '02, surpassing that of gray iron. Pressure Pipe--Ductile iron pipe (which represents 45% of all ductile iron shipments) is forecast to rebound this year to 1,845,000 tons and return to 1.9 million-ton levels in '03. A long-term annual growth of 2.6% is forecast to reach 2.4 million tons by '09. Motor Vehicles--Last year, ductile iron consumption in light vehicles declined 19%. Shipments for light vehicles should see 4% growth in '02 and 16% in '03. The average weight of ductile iron per light vehicle is expected to fall from current 190 lb levels to 170 lb over the next 10 years. After ductile ductile /duc·tile/ (duk´til) susceptible of being drawn out without breaking. duc·tile adj. Easily molded or shaped. ductile susceptible of being drawn out without breaking. iron's use in medium-to-heavy trucks fell 30% to a 10-year low, shipments to this sector are forecast to increase 19.5% to 196,000 tons in '02 and rise another 30% in '03. Valves & Fittings--Ductile iron valves are expected to increase 4% this year to return to '00 levels of 222,000 tons and grow 3.5% annually. Ductile iron is expected to be substituted for malleable iron (Metal.) iron sufficiently pure or soft to be capable of extension under the hammer; also, specif., a kind of iron produced by removing a portion of the carbon or other impurities from cast iron, rendering it less brittle, and to some extent malleable. in future threaded pipefitting applications. Imports are estimated to increase to 38% of shipments, primarily from the Asia. Special Industry Machinery--Ductile iron shipments are expected to increase 7% this year to 101,000 tons and grow 3.3% annually in the long term. Growth in consumption for printing, paper, packaging, and plastic machinery applications is forecast. Farm Machinery & Equipment--Ductile iron shipments grew slightly last year and are forecast to continue to grow 5.5% in '02 to 115,000 tons. An annual growth rate of 3% is forecast. Construction Machinery & Equipment--A 2.7% rebound in ductile iron tonnage is forecast this year to 190,000 tons. This is expected to be followed by a 10% growth in '03, spurred by the replacement of steel and gray iron. A long-term annual growth rate of 3% is expected. Gears and Power Transmission Equipment--Casting shipments are expected to increase 8% to 27,000 tons in '02. The long-term growth in the use of ductile iron in this market sector is forecast to be assisted by the conversion of forgings to austempered ductile iron and reach 3.1% annually. Oil Field Machinery--A third consecutive year of growth is forecast this year to 64,000 tons, followed by a 10% growth in '03. Malleable Iron Malleable iron casting shipments are estimated to drop 6% to 140,000 tons this year and continue to drop 8% annually to 65,000 tons by '11 as the conversion to ductile iron is completed. Pipe Fittings--Imports (primarily from the Asiatic countries) comprise 40% of the shipments of threaded pipefittings and have reduced domestic annual shipments to 40,000 tons. Further conversion to ductile iron is expected to reduce domestic shipments to 32,000 tons. Motor Vehicle--The anticipated closing of General Motors' malleable iron foundry in Saginaw, Michigan Saginaw is a city in the U.S. state of Michigan. As of the 2000 census, the city had a total population of 61,799. The 2006 population estimate was 57,523.[1] It is the county seat of Saginaw County[2] , should accelerate the conversion of malleable iron parts to ductile iron and lower malleable malleable /mal·le·a·ble/ (mal´e-ah-b'l) susceptible of being beaten out into a thin plate. mal·le·a·ble adj. 1. Capable of being shaped or formed, as by hammering or pressure. tonnage to 16,000 tons in 10 years. Steel Steel casting Steel casting is a manufacturing process in which molten metal is poured into a mold, allowed to solidify within the mold, and then the mold is broken and the solid piece is taken out. shipments are forecast to rebound 7% to 1,257,000 tons this year as railroad shipments increase from last year's low. Long-term, an annual growth rate of 1.7% is forecast. Carbon & Low Alloy alloy (ăl`oi, əloi`) [O. Fr.,=combine], substance with metallic properties that consists of a metal fused with one or more metals or nonmetals. Steels--Based on an increase in specific market sectors, a 7.3% growth to 1,071,000 tons is forecast in 02. Shipments of carbon and low alloy steel Low alloy steel is steel alloyed with other elements, usually molybdenum, manganese, chromium, vanadium, silicon, boron or nickel, in amounts of up to 10% by weight to improve the hardenability of thick sections. castings are forecast to grow in the long term at a 1.6% annual rate. Railroad--Freight car deliveries contracted to 32,000 units in '01 but are expected to rise to more than 40,000 cars in '02, spurring a 50,000-ton increase for carbon steel castings. In the long-term, a return to 50,000- and 60,000-unit car sets is forecast. Shipments should increase at an annual rate of 2.2%. Mining Machinery and Equipment--Consumption of carbon and low alloy steel castings in mining machinery grew 13% last year and is expected to grow an additional 5% in '02 to 94,000 tons. A long-term growth of 1.7% annually is forecast. Construction Machinery & Equipment--Steel casting shipments for construction machinery are expected to rebound 2.6% to 197,000 tons this year as construction activity bounces Bounces is a 1985 sports/fighting game released for the Commodore 64 and ZX Spectrum. Points are scored by catching and throwing the bouncing ball into a goal, or by knocking the opponent out with the ball or hand-to-hand combat. back. Long-term growth of carbon steel shipments is forecast at 1.5% annually. Valves--Carbon steel valve production is expected to be depressed for the seventh straight year in '02. A 9% increase is forecast in '03, followed by a 2.3% annual growth rate to 90,000-ton levels by '08. Trucks--Steel casting truck applications, helped by usage in military vehicles Military vehicles include all land combat and transportation vehicles, excluding rail-based, which are designed for or are in significant use by military forces. See also list of armoured fighting vehicles. , should see a 6% increase in '02. The long-term forecast, however, calls for a gradual decline of 2.9% per year as conversion of parts to ductile iron continues. Corrosion-Resistnat Steels--Shipments of corrosion-resistant cast steels are forecast to grow 6.7% in '02. Long-term shipments are expected to grow 3.2% from 74,000 tons in '01. The major annual growth rates Growth Rates The compounded annualized rate of growth of a company's revenues, earnings, dividends, or other figures. Notes: Remember, historically high growth rates don't always mean a high rate of growth looking into the future. are found in valves (3.5%) and pumps (3.2%). Food product machinery also offers good growth potential. Heat-Resistant Steels--Heat-resistant steels are forecast to rebound 13.7% in '02 and grow at an annual rate of 2.3% from last year's 29,000 ton-total as industrial process furnace furnace, enclosed space for the burning of fuel. There are many kinds of furnaces, the type depending upon the fuel and the use to which the heat produced within it is put. Most familiar are the furnaces used in the heating of buildings. applications return to annual levels of 15,000 tons. Manganese manganese (măng`gənēs, măn`–) [Lat.,=magnet], metallic chemical element; symbol Mn; at. no. 25; at. wt. 54.938; m.p. about 1,244°C;; b.p. about 1,962°C;; sp. gr. 7.2 to 7. , Wear-Resistant and Other Steel Castings-Manganese steel casting shipments, spurred by growth in mining equipment applications, are expected to grow 8% to 40,000 tons in '02 and to 51,000 tons by '07. Wear-resistant martensitic steels also are expected to increase to 38,000 tons in the same period. Aluminum Shipments of aluminum castings are forecast to increase from 1,870,000 tons in '01 to 2,645,000 tons in 11, an annual growth rate of 3.5%. increase in shipments of 9% is expected in '02 to 2 million tons. In terms of processes, die sting (which represents 58% of all aluminum castings produced) is expected to see a long-term growth rate of 2.5%. Meanwhile, the permanent mold/sand processes (including ding 1. ding - Synonym for feep. Usage: rare among hackers, but commoner in the Real World. 2. ding - "dinged": What happens when someone in authority gives you a minor bitching about something, especially something trivial. "I was dinged for having a messy desk." low-pressure permanent mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. and lost foam) are expected to see a 4.9% annual growth rate. A 13.6% increase (to 519,000 tons) for permanent mold/sand processes is expected for '02 as automotive production increases and engine block conversions to the sand processes increase. Motor Vehicles--Aluminum casting shipments for use in motor vehicles dropped 12% in '01 despite the conversion of many parts from cast iron. A rebound of 12% is forecast for '02 to 1.2 million tons. Aluminum casting weight a weight that turns a balance when exactly poised. - B. Trumbull. See also: Casting per vehicle is expected to rise from 210 lb to 270 lb in '10 as casting growth of 4.4% per year is forecast for the long term. Internal Combustion Engines--An increase to 108,000 tons in '02 is expected from last year's low 100,000-to year. Shipments for non-automotive gasoline gasoline or petrol, light, volatile mixture of hydrocarbons for use in the internal-combustion engine and as an organic solvent, obtained primarily by fractional distillation and "cracking" of petroleum, but also obtained from natural gas, by and diesel engines are forecast to grow at an annual rate of 3.3%. Aluminum is expected to grow with the increase gasoline marine and lawn/garden engines. Refrigeration & Air Conditioning--Aluminum consumption in small compressor bodies in refrigeration and air conditioning units is growing at an annual rate of 3.2%. Die cast aluminum parts are used in scroll-type Compressors. The annual usage of aluminum in this market sector has remained fairly constant for the past 7 years at 50,000 tons. Aircraft & Parts--Military aircraft sales are expected to boost aluminum casting consumption in aircraft y 6% to 88,000 tons in '02 and grow to 100,000 tons in the next 5 years. Instruments--A 9.4% increase (to 104,000 tons) is forecast for cast aluminum se in engineering, scientific, measuring, controlling, optical and analytical analytical, analytic pertaining to or emanating from analysis. analytical control control of confounding by analysis of the results of a trial or test. instruments and photographic and photocopying photocopying, process whereby written or printed matter is directly copied by photographic techniques. Generally, photocopying is practical when just a few copies of an original are needed. When many copies are required, printing processes are more economical. equipment. A long-term growth rate o 3.4% is expected. Copper-Base After dropping 7% to 302,000 tons last year, copper-base castings are expected to see minimal growth in '02 before rising to 314,000 in '03. A long-term growth rate of 0.8% is forecast as plastics continue to be substituted for many parts. Plumbing plumbing, piping systems inside buildings for water supply and sewage. The Romans had a highly developed plumbing system; water was brought to Rome by aqueducts and distributed to homes in lead pipes—hence the name plumbing from the Latin word plumbum & Sanitary Fixtures/Fittings--A second-consecutive 10% decline is forecast for '02. A long-term rate of decline of 1% is forecast based on the continuing substitution of wrought parts and plastics. Imports are also increasing. Industrial Valves & Fittings--Imports have now risen to 21% of shipments and have affected pricing as well as market conditions. Shipments are predicted to grow 4% to 104,000 tons in '02 and stay fairly constant in the long term. Zinc A 3.6% increase to 309,000 tons is forecast for zinc die castings die casting Forming metal objects by injecting molten metal under pressure into dies or molds. An early and important use of the technique was in the Linotype machine (1884), but the mass-production automobile assembly line gave die casting its real impetus. in '02 based on the expected increase in motor vehicle production. Shipments of zinc and lead-base alloy die castings are expected to continue to decline at a rate of 0.1% per year to 294,000 tons in '11. Magnesium magnesium (măgnē`zēəm, –zhəm), metallic chemical element; symbol Mg; at. no. 12; at. wt. 24.305; m.p. about 648.8°C;; b.p. about 1,090°C;; sp. gr. 1.738 at 20°C;; valence +2. Continuing to be substituted for aluminum and plastics, cast magnesium shipments have grown by 35% in as few as four years, including last year's 5% growth to 78,000 tons. A 7.6% increase is forecast for '02. Forecasts call for magnesium to capture the following share of the market in these light vehicle components by '05: wheels (8%), pistons Pistons can mean:
fuel system - equipment in a motor vehicle or aircraft that delivers fuel to the engine (7%), rocker arm cover (20%) and transmission case (10%). A 12% annual rate is expected over the long-term, assisted by fuel economy standards that will favor magnesium's use. Investment Castings investment casting Precision casting for forming metal shapes with minutely precise details. Casting bronze or precious metals typically involves several steps, including forming a mold around the sculptured form; detaching the mold (in two or more sections); coating its A surge of imports from China caused a sudden drop in domestic investment casting shipments in '99 to 154,000 tons. The downturn, plus continuing imports, has reduced shipments further to 145,000 tons in '01. An increase to 159,000 tons is forecast in '02 as imports have stabilized sta·bi·lize v. sta·bi·lized, sta·bi·liz·ing, sta·bi·liz·es v.tr. 1. To make stable or steadfast. 2. at about 10% of the total and growth is expected in the commercial valve and pump and sporting good sectors. Long-term, a 3.1% growth rate is forecast. This article was abstracted from the 2002 AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System. AFS - Andrew File System Metalcasting Forecast & Trends published by AFS. Included in the larger report are details on casting supply and utilization, global casting production, imports/exports and historical trends. The report may be purchased from AFS Publications (800/537-4237, ext. 241) for $50 off the list price prior to February 1. [Graph omitted] Revised Forecast for U.S. Metalcasting Shipments (Thousands of Tons) Metal 2000 2001 2002 Gray Iron 5631 5022 4967 Compacted Graphite Iron 68 66 68 Ductile Iron 4321 3929 4080 Malleable Iron 204 149 140 Steel 1364 1170 1257 Alum. Die Casting 1210 1101 1196 Alum. Permanent. Mold/Sand 842 769 846 Copper Base 325 302 303 Zinc/Lead 347 298 309 Magnesium 74 78 84 Other Nonferrous 47 45 46 Investment Cast 156 145 159 TOTAL 14,589 13,074 13,455 Gray Iron Markets--Annual Rates of Growth and Decline (2001-2011) (*) GROWTH MARKETS AGR DECLINING MARKETS AGR Machine Tool +2.5% Household Appliances -7.6% Internal Combustion Engine +2.3% Ingot Molds -5.9% Refrigeration/AC +2.0% Sanitary/Radiator -4.3% Farm Equipment +1.9% Soil Pipe -3.8% Pumps & Compressors +1.8% Passenger Car/ Light Truck -2.2% Gears, Power Transmission +1.6% Electric Motor -1.8% Special Industry Machinery +1.5% Roll Machinery -0.9% Municipal, Highway, Street +1.1% Valves & Fittings +1.0% (*)annual rates based on 2001 base year Ductile Iron Markets--Annual Growth Rates (2001-2011) (*) Industry Annual Growth Rate Medium to Heavy Truck +3.5% Special Industry Machinery +3.3% Gears, Power Transmission +3.1% Construction Equipment +3.0% Farm Equipment +3.0% Valves & Fittings +3.0% Diesel Engines +3.0% Pumps & Compressors +3.0% Refrigeration & AC +3.0% Pressure Pipe +2.6% Oil Field Equipment +2.0% Passenger Car/Light Truck +0.8% (*)annual rates based on 2001 base year Steel Markets--Annual Growth Rates (2001-2011) (*) Industry AGR Special Industry Machinery +3.2% Pumps +2.8% Valves +2.6% Railroad +2.2% Oil Field Equipment +2.1% Mining Machinery +1.9% Construction Machinery +1.5% (*)annual rates based on 2001 base year Aluminum Casting as a Percent of Total Light Vehicles Produced in the U.S. Part 2002 2004 2006 2009 Engine Block 30% 50% 62% 74% Cylinder Head 85% 90% 96% 98% Intake Manifold 50% 30% 28% 16% Transmission Case 95% 95% 94% 92% Wheels 70% 75% 78% 80% Suspension Parts 5% 15% 18% 25% U.S. Casting Supply & Utilization Rate--2002 Metal Capacity (Thousands of Tons) Utilization (%) Iron 12,350 75 Steel 1700 74 Aluminum 2560 80 Copper-Base 380 80 Magnesium 100 84 Zinc 410 75 Other Nonferrous 60 77 Investment 210 76 Total Metalcasting 17,770 76 RELATED ARTICLE: Snapshet at the U.S. Casting Industry--2002 Facilities: The U.S. casting industry is now estimated at 2770 operations (down from 3200 in '91) and is currently operating at about 76% usable USable is a special idea contest to transfer US American ideas into practice in Germany. USable is initiated by the German Körber-Stiftung (foundation Körber). It is doted with 150,000 Euro and awarded every two years. capacity. The largest casting-producing states are Ohio (15%), Alabama (11.6%), Wisconsin (11.4%), Indiana (11.2%) and Michigan (8%). About 225,000 are employed by the casting industry nationwide. Markets: Last year's casting shipments were valued at $27 billion. The major markets for domestic castings are automotive/light truck (35%); pipes & fittings (15%); construction, mining & oil field equipment (6%); internal combustion engines Internal combustion engine A prime mover, the fuel for which is burned within the engine, as contrasted to a steam engine, for example, in which fuel is burned in a separate furnace. (5%); railroad equipment (5%); valves (5%); farm machinery (3%); municipal castings (3%); and pumps/compressors (2%). The U.S. is the world's largest casting user and producer (leading all metal groups with the exception of gray and malleable iron, both of which are led by China). Imports: Compounding recent economic difficulties is the fact that imported castings continue to grow, now representing 14% of the total demand in the U.S. The most significant effects of imports are felt in diesel engines (39%), valves/fittings (36%), municipal/construction (32%) and motor vehicles (17%). In terms of metals, the import situation is as follows: gray iron engineered castings (819,000 tons), ductile iron engineered castings (322,000), aluminum die castings (94,000) and non-railroad steel castings (94,000). |
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