Metalcasting:Who and What Are We?

What is Metalcasting?• Metalcasting is a process in which molten metal is poured

into a mold to form complex parts• All major metals can be cast• Metal castings are used everywhere.

Metal Casting Facts• Most anywhere in the U.S.,

you are never more than 10 ft. from a metal casting

• 90% of all manufactured goods contain metal castings

Metal Castings Are Everywhere

Profile of the U.S. Metalcasting Industry

1965 Operating Metalcasters– 700 Ferrous; 1300 Nonferrous– Employ 200,000– 80% Are Small Businesses with less

than 100 employees– 2013: $31 Billion Sales;

12 Million Tons Shipped– Global Leader in Casting

Application; 2nd in Production

What Metals Are Used in

Metalcasting?

Where are castings

used?

Career Opportunities

• science?• to build things?• to design things?• to be creative?

Do You Like:

Careers: Post High School

• Molder, Melter & Welder: $16+/hr• Patternmaker, Crane Operator: $17+/hr• Maintenance & Electrician: $20+/hr

Plant Floor Positions:

Careers: Post College

• Supervisors-Plant Floor: $50,000+/yr• Production, Quality, Safety Mgr: $60,000+/yr• Top Mfg, HR, Eng Exec: $90,000+/yr

Supervisors & Management

Engineering Degree & Engineering Technology Degree

More Math/Science More “Hands on”

Average Starting Salaries for Engineering Graduates

Engineering Median Annual Salaries

The Oscar

• Cast By R.S. Owens, Chicago

• Cast via Permanent Mold in Britannia, a Copper-Base Alloy

• 8.5 lb, 13.5 in. Tall• Casting is Plated in

Copper, Nickel, Silver and 24K Gold

Screen Actors Guild Award

Ice Cleat for the M1 Abrams Tank

• Made of 8630 Steel and Cast in Green Sand by Varicast, Portland, OR

• Redesigned to a Casting From a Steel Forging

• Casting Must Withstand Temperatures to -40 F

Golf Clubs

Golf Clubs

• ‘Metal woods’ and ‘irons’ are cast in stainless steel and titanium

• High strength material provides hardness that transmits maximum energy to the ball

• Titanium provides the strength of steel at half the weight

GM SUV Engine Block

• Aluminum Cylinder Block for GM’s Vortec 4200 SUV Engine Cast via Lost Foam

• In Lost Foam, a Polystyrene Pattern is Produced and Repalced with Molten Metal to Form the Casting

Cell Phone Keypad and Display

• Cast in Magnesium via Thixomolding Casting Process.

• The Casting’s Walls Are 0.8-1 mm Thick, with a Total Casting Weight of 105 gms

• Converted from a Plastic Part to Magnesium

Questions?