METAL MOLD CASTING -- UNITED STATES

In order to establish a context, the following observations are made regarding metal mold casting in the United States:

• The highest growth of all the various metal mold casting technologies in the United States is in the high pressure, fast fill die casting industry because of the resultant productivity, net shape, and excellent dimensional tolerance achieved
• Significant growth is seen in the application of low pressure, semipermanent mold (SPM) casting technology to the automotive industry because of the resultant cast part quality, effective cost, and metal yield
• High pressure, fast fill metal mold casting technology is moving toward thinner walls requiring even faster fill and hotter die temperatures
• Permanent mold (PM) and SPM casting technologies are used for improved properties over die casting
• The high pressure, slow fill squeeze cast process has better dimensional tolerance and productivity when compared to SPM or PM, but the capital cost involved is very high and may be viewed as a barrier to entry
• Product developments and production capacity in semisolid casting -- specialized processes -- are now available
• High growth is observed in high pressure, fast fill magnesium parts
• Both semisolid casting and the high pressure, slow fill squeeze cast process at present lack design and process standards
• Price competition among all metal mold casters in the United States limits capital and development resources