Global metal casting production is expected to reach 115-million tons by 2015, but the role South Africa plays in the global industry continues to decline.

American Foundry Society marketing, communications and public relations director Alfred Spada says the number of South African metal casting facilities has reduced from 255 in 2006 to 180 as a result of challenges such as rapidly increasingly energy and labour costs, a lack of access to capital and skills devel- opment and training.

The metal casting facilities in South Africa comprise 43 iron, 53 steel and 84 nonferrous foundries, which collectively produced 424 000 t in products in 2011.

This ranks the country as nineteenth in casting production worldwide, ahead of Pakistan and behind the UK and the Czech Republic.

Global metal casting production was led by China, the US and India in 2011.

China was the top global producer, with 41.3-million tons from 30 000 plants, followed by the US, which produced 10.33-million tons from 2 040 plants, and India, with 9.99-million tons from 4 500 plants.

Spada says metal casting is a global growth industry, with many strengths, weaknesses, opportunities and challenges, and urges all foundries to approach fellow metal casters to improve business, processes and technologies to sustain the industry.

He stresses that the adoption of the latest technologies to improve efficiency and decrease the impact on the environment, as well as new market opportunities to create diversity and meet market demands, is important for the industry’s success.

Technology development strengthens the industry and includes simulation modelling for more efficient casting design, vacuum- and pressure-assisted casting processes and automated pouring.

Further, Spada says the industry is perceived as old, dirty and dangerous. Therefore, there is a need for new and younger leadership to be involved in the developments, opportunities and marketing of the industry to provide employment opportunities for the younger generation, he notes.

“Despite the challenges created by governments and the regulations on climate change, environmental agencies and worker safety, as well as on alternative processes and materials, such as weldments and plastic and powder-metal parts, there are opportunities for the metal-casting industry,” Spada states.

New markets, customer education, rapid prototyping and conversions to casting are opportunities that need to be investigated and implemented to develop the industry.