ITP Metal Casting: 2002 Metal Casting Industry of the Future ...

THE CHALLENGE
Metal casting is one of the most energy-intensive industries in the U.S. manufacturing sector. It is
also one of the only major U.S. manufacturing industries that is dominated by small businesses.
These unique characteristics have helped drive the need for public-private R&D collaboration.
Energy-Intensive Industry
In 1998, the U.S. metal casting industry (NAICS 3315) spent $1.2 billion purchasing an estimated
235 trillion Btu. The amount of energy used by the metal casting industry is equivalent to that used
by residents in New Hampshire, New Mexico, Rhode Island, Wyoming, and Hawaii combined. 1 If
captive foundries are included, the estimated energy consumption for metal casting increases to
328 trillion Btu. 2
Energy intensive processes in metal casting include melting, mold making, core making, and other
activities. (Energy Use in Metal Casting, page 7). The Metal Casting Industry of the Future is
funding research to improve energy efficiency in these processes. This research is improving yield,
extending die and mold life, and reducing post-cast energy requirements. A 2002 analysis of
current Metal Casting IOF research projects estimates that the current R&D portfolio will save 23.4
trillion Btu annually in 2010. This is estimated to increase to 101 trillion Btu in 2020.
Metal casting R&D is a component of the overall EERE strategy to improve energy efficiency
nationwide and to contribute to the goals outlined in the National Energy Policy. It is contributing to
the EERE mission “to strengthen America’s energy security, environmentally quality, and economic
vitality through public-private partnerships that:
1. promote energy efficiency and productivity;
2. bring clean, reliable, and affordable energy technologies to the marketplace; and
3. make a difference in the everyday lives of Americans by enhancing their energy choices
and their quality of life.” 3
Small Business Industry with a Nationwide Impact
The majority of metal casters are small businesses. Eighty percent of the estimated 2,950 metal
casting facilities employ fewer than 100 people, 14% employ between 100 and 250 people, and
only 6% employ more than 250 people. Industry-wide, an estimated 225,000 people are employed
in metal casting. Moreover, the industry is widely dispersed throughout the country, eliminating
opportunities for geographic based intra-industry coordination. In fact, metal casters are located
throughout all 50 states. The industry is vital to the economic well being of the communities where
they are located. Although the industry is found nationwide, ten states account for 84% of metal
castings shipments. These states are Ohio, Indiana, Wisconsin, Alabama, Michigan, Pennsylvania,
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Illinois, Tennessee, California, and Texas.
1 1998 Manufacturing Consumption of Energy Report, U.S. Department of Energy, Energy Information Administration Tables N.11.1,
and Survey 1998 Annual Energy Review, U.S. Department of Energy, Energy Information Administration, Table 1.6
2
Using AFS 2002 MetalCasting Forecast & Trends, the ratio of metal casting shipments (NAICS 3315) to captive foundry casting
production was calculated. This ratio was applied to industry energy consumption for NAICS 3315,1998 Manufacturing
Consumption of Energy Report, U.S. Department of Energy, Energy Information Administration Tables N.11.1 , to estimate energy
consumption in captive foundries.
3 U.S. Department of Energy, Assistant Secretary for Energy Efficiency and Renewable Energy, Organization Mission and Functions,
2002, pg.1
4
www.afsinc.org/Trends/FactsandFigures.htm 3