Visiting Research Fellow Monograph Series

This series aim at disseminating the results of research done by Visiting Research Fellows at the Institute of Developing Economies. However, no part of this paper may be quoted without the permission of the author, since some of the results may be preliminary. Further, the findings, interpretations and conclusions expressed in this paper are entirely those of the author(s). Paper does not imply endorsement by the Institute of Developing Economies of any of the facts, figures, and views expressed. The Institute of Developing Economies does not guarantee the accuracy of the data included in this paper and accepts no responsibility whatsoever for any consequence of their use.

Summary

70

Top-down

Bottom-up

1415

45 58

60

2083

5096

20034.52004

8.41997

70 2000

200411

2.3513

47.7

1999

80

2004185

11

10

1998656.1

3011.3

95

Win-Win

()

AutomaticClean

Easy

matching fund

i

3

3

3

4

6

6

7

9

11

13

13

13

16

18

18

26

33

42

42

44

ii

46

48

51

51

55

56

57

60

60

60

65

68

69

iii

. 8

.. 14

.. 15

.. 15

.. 19

.. 21

.. 23

..2004 24

.. 25

..19932000 27

..19951997 28

.. 29

..19991997 31

..10 38

..11 39

.. 43

.. 43

..2004 45

.. 46

iv

..2002 52

..2005 55

.. 56

..2005 56

v

. Value Chain 3

. 9

. 10

. 10

.. 13

.. 18

.. 20

..19992003 21

.. 22

.. 23

.. 27

..19931999 29

..1998 30

.. 34

.. 35

..10 36

..11Metal Casting Industry of the Future 38

..1219912000 40

vi

..2004 44

.. 45

.. 51

.. 52

..2002 53

.. 54

.. 61

.. 62

.. 63

1

27

2210

2

3

.Value Chain

4

221030

1035

70

200220102010

2010

90

Top-down

Bottom-up

5

Expert Systeme-Manufacturing

6

.

1415

455860

835096

7

- 20

- 10.13.31.6

3517

- 1413

- 128

- 2050

- 32.618

- 71

- 15111

- 50 300

- 12251400

314

- 3631

8

.

425.9 1860.7 5149.7

1998.0 1991.7 1987.6

10.1 32.6 122.4

1426.6 5854.5 39996.3

151.1 322.2 614.3

128.2 151.4 313.5

50.5 70.6 47.6

13.7 10.6 6.3

12.4 11.1 22.0

0.13 0.10 0.06

9

.

2524

29

94

86251

10

.

233(25%)

19(2%)

220(24%)

264(29%)

23(3%) 6

(1%)

10(1%)

11(1%)

132(14%)

0

50

100

150

200

250

300

.

122(14%)

438(51%)

250(29%)

52(6%)

0

100

200

300

400

500

.

11

-

- 2005370

11.18.8

10

-

-

- 2005

7.2

- 199711.7

-

-

- 200010

-

-

- 200517.8 -

20002,80020033,800

12

178

21

13

1

..

14

..

15

..

..

273

2731

27311

27312

2732

27321

27322

27329

16

0.2223

90

17

-

18

..

20034.520048.4

199770

2000

6.3199714

19

200411

2.3513

..

2001 2002 2003 2004 2001 2002 2003 2004

1 14,889 16,262 18,145 22,420 21.8 23.2 24.6 28.1

2 11,871 11,812 12,069 12,314 17.4 16.9 16.4 15.4

3 5,841 5,752 6,111 6,386 8.6 8.2 8.3 8.0

4 6,200 6,200 6,200 6,200 9.1 8.9 8.4 7.8

5 4,643 4,595 4,722 4,984 6.8 6.6 6.4 6.2

6 3,155 3,267 4,038 4,623 4.6 4.7 5.5 5.8

7 2,527 3,018 2,484 2,465 3.7 4.3 3.4 3.1

8 2,393 2,441 2,441 2,441 3.5 3.5 3.3 3.1

9 1,760 1,971 2,249 2,829 2.8 2.9 2.8 2.7

10 1,880 2,030 1,822 2,185 2.6 2.8 3.0 3.5

11 1,683 1,714 1,783 1,875 2.9 2.7 1.6 1.6

12 1,970 1,888 1,221 1,273 2.5 2.4 2.4 2.35

13 1,572 1,628 1,149 1,309 2.3 2.3 1.6 1.6

14 1,210 1,441 1,468 1,451 1.8 2.1 2.0 1.8

15 1,369 974 974 974 2.0 1.4 1.3 1.2

68,311 70,029 73,554 79,745 92.2 92.8 90.9 92.5

: American Foundry Society, Modern Casting 2004.

20

..

..

19972003

5070

21

..19992003

0

2

4

6

8

10

12

14

16

18

20

:

1999

2003

..

..

2004 2004

1 2,242 1,686 75

2 1,231 842 68

3 638 462.7 72

4 6202003 570 92 2003

5 498 390 78

6 462 366 79

7 246 194 79

8 244 121.4 50

9 282 237.6 84

10 218 142 65

11 185 155.9 84

12 145 100.5 69

13 130 105.7 81

..

22

..

..

80

2416

1024

1211

..

12,000

1990

4,200

23

..20032004

20032004

1 12,000

2 4,5004,200

3 2,6002,380 681619 288262 1,6511,499

4 2000 1,900

5 2003 1,787 741 27 1,019

6 1,7131,708 457457 8078 1,1761,173

7 1,1391,106 232210 2727 880869

8 1,057888 904736 6968 8484

9 1,0001,315 - 486 - 145 - 684

10 2002 960 400 233 437

..

..

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

..

24

10

..

10

..2004

2004

1 7,776

2 5,174

3 4,732

4 3,739

5 2,327

6 2,207

7 2,152

8 1,868

9 1,223

10 1,100

..

25

Squeeze CastingFoundry Ceramics

Lost Foam CastingInvestment

Casting

Rapid PrototypingLost Foam CastingSemi-permanent Casting

..

-

-

-

-

2004

26

20042003200423.6

70

..

19932000

1999 50

1996

2002

27

..

..19932000

:

1993 1994 1995 1996 1997 1998 1999 2000

8,250 7,607 7,303 6,945 6,875 6,305 7,912 8,639 -

1,267 1,321 1,341 1,343 1,564 1,431 2,063 2,333

404 364 422 367 354 293 359 400

1,722 1,610 1,578 1,404 1,453 1,304 1,353 1,542

120 100 104 92 96 96 107 119 -

467 475 530 594 660 686 735 799

50 52 51 63 76 77 115 118

71 74 - - - - - - -

12,355 11,606 11,332 10,903 11,080 10,194 12,647 13,954

..

28

..19951997

:

1995 1996 1997

1,178,000 1,190,000 1,274,600 11.4

714,000 700,200 690,700 6.2

1,940,000 1,901,300 1,932,200 17.4

687,000 664,000 657,600 5.8

426,000 407,000 414,200 3.7

2,026,000 2,005,000 1,981,700 17.8

374,000 358,000 349,900 3.0

200,000 123,900 110,500 0.9

1,836,000 1,674,000 1,715,000 15.4

459,000 445,000 433,500 3.8

1,492,000 1,434,785 1,520,542 13.7

11,332,000 10,903,185 11,080,442 100

..

11.7

33

17.417.815.4

62

3001997

0.1

29

..

300 4040 33.7

3012,000 3440 28.6

2,0015,000 2936 24.7

5,00110,000 1454 12.1

10,000 103 0.1

12000 100

..

..19931999

..

30

1980

1999110

..1998

Mid-low grade29 500mm

0.648.96.6

9.80.4

360.02

High grade

Mid-high

grade18Mid-

gradeNon-industrial1735

..1998

..

31

30

199059.4

3.1

..19951997

:

1995 1996 1997

290,000 317,250 356,468 3.1

1,460,000 1,420,000 1,360,000 12.2

550,000 480,370 350,000 3.1

V- 140,000 138,000 145,000 1.2

7,392,000 6,667,707 6,597,974 59.4

250,000 276,358 312,000 2.7

50,000 58,500 68,000 0.6

30,000 74,000 96,000 0.8

170,000 181,000 190,000 1.7

1,000,000 1,290,000 1,605,000 14.4

11,332,000 10,903,185 11,080,442 100

..

32

15

20

403010

steel

1989

1,2002000

300

Institute of Metals Research

1953

986300Shenyang Laboratory

Materials Science Shenyang R&D Center for Advanced Materials 12

Research DivisionShenyang National Laboratory for Materials

33

ScienceOpen LabChinese Journal of

Materials ResearchJournal of Materials Science and TechnologyActa

Metallurgica Sinica

197394

1505003,500

2000ISO9000

2004Volkswagen

Makita

2001

2003

100380

195200315

1970

902,000

1980

34

19901,1301990

1998

1,410180200113

1,220169

ductile cast iron

..

2004

35

..

: American Foundry Society, Modern Casting 2004.

36

30 19992003

2001

3010

35

..10

..

37

10080

10025014250

225,000

20002001

2002

2003

47soil/pressure pipe20

4711

1995 Beyond 2000: A Vision for the American

Metalcasting Industry2020

Net-

Shape

1998'Metalcasting Industry Technology Roadmap'

Department of EnergyOffice of the Industrial

Technologies

38

..11Metal Casting Industry of the Future

..

..10

-

-

-

-

- Lead Time

-

-

-

-

-

-

- Rapid Tooling

-

- Pattermaking

- SizeDimension

-

-

-

- Fold for Aluminum Lost Foam Casting

-

-

-

- Waste Stream

- Emission Database

..

39

..11

2020

Advanced

Melting

Energy Benchmark Study

Theoretical Minimum Study

Gran Challenge Solication

Yield

Improveme/Scrap

Reduction 10

Energy Savings 10

Emission Reduction

20

Innovative

Casting

Processes

Thin Wall/High Strength

Machining; Inclusions;

Porocity Reduction

Steel Foundry Practices

Sensors

Diecasting Practices

Materials Properties and Performance

Computer-based Modeling

Tools

R&D

Integration

System

Analysis

Casting Facility Practices

Plant Systems

Energy Guidelines; Emission

Reduction; Byproduct Reduction

..

Metal Casting Industry of the Future

American Foundry Society North American Diecasting

Association Advanced Technology Instute

Steel Founder's Society of AmericaCast

Metals Coalition

Metal Casting

20

1991

40

..1219912000

..

5030250

199120001998

70

Metal Casting Industry of the Future

Net-shape Production

41

Metals Process Simulation Lab.

Continuous Casting ConsortiumNational Science foundation

Ingot Metallurgy Forum

Simulation

Hydro Magnesium

100KT

GM

Life Cycle Inventory

Ames LaboratoryIOWA State University

50

42

2004185:

11

10

1998656.1

3011.3

19701990

1997

1990

2004600

20032005

200535,998

23,400

43

..

:

2003 2004 2005

1,001,840 1,041,914 1,094,009

539,840 551,434 600,734

50,960 52,998 37,098

152,320 158,413 166,333

1,744,960 1,784,758 1,898,174

20,720 21,756 23,279

42,000 43,890 48,279

5,488 5,762 6,281

68,208 61,408 77,839

1,813,168 1,856,167 1,976,013

..

1999 2005

profile 3,992 9,654 17,112 1,670

1,225 518 280 1,081

5,472 7,792 26,208 10,401

858 10 50 401

89 2 34 -

7 402 60 723

96 2,012 1,592 83

21,755 29,596 71,571 44,428

3,458 26,147 20,563 36,141

1,497 2,753 11,392 4,225

6,326 30,626 33,695 45,653

44,775 109,512 182,544 146,546

..

44

..2004

200511

1990

19601991927

2004600

2004

2009050

45

58

..

..

..2004

75 117 192

22 87 109

57 144 201

- 98 98

146 436 600

..

46

..

1981 1993 2004

3.96 10.7 10

43.6 20.6 20

52.4 68.7 70

100.0

..

19811993

10

1981442004

20

99

47

42

2.1

91.5

300

48

2003

2010

2010

:

-

- 2010

49

2004

pilot plant

online network

50

10 -> 60

-> zero

zero

bulk

near net shape

51

47.72005670

563107

1980 1980

8.5198514.51990

12.4

1990772

..

52

..

..2002

: American Foundry Society, Modern Casting 2004.

20022005

10738

53

..ductile

cast iron

..2002

54

1980

10020100

2005

512612

..

55

20051,154100

97

30

650

2005

42.6136.8

16099

..2005

100 5099 2049 19

75 119 281 579 1,154

7 97 100

31 69 100

200511

56

..

1975 1985 2005

3,279 2,072 1,154

100,159 78,932 41,152

5.49 6.58 5.63

54.9 83.4 136.8

1,675.5 3,176.4 5,828.2

30.5 38.1 42.6

..

..2005

47441 736.3 60752.7 1,154100.0

..

10

57

21

2005

Magneto-Hydrodynamics

Cast Metal Matrix Composite

58

2

Curtain WallScrap Metal

Nodular Iron Container

Phase Selection

Division of Foundry Engineering

EutecticHyper eutectic Al-Si

Shell

Soft Contact Steel Casting

Single-Shot

Carbon Steel core

Cladding

Magnetostriction

National Industrial Research Institute

of Nagoya

59

Super Metals Program

Compocasting

Hot Isostatic PressingCold Isostatic Pressing

Skid

Button

Porous

Exhaust

Manifoldmm

60

61

21

..

62

..

63

Life Cycle Assurance

..

64

Built-In House Environment Facility'

14000

chip

briquettechip briquette

Binder

stainless cast iron

65

mono-body

rapid-prototypingE

24one-stop

Cladding

Win-Win

66

Dangerous, Dirty, Difficult

AutomaticCleanEasy

High integrityNear-net

shape

67

10

100

Win-Win

Dimension Free Casting

Seed

68

69

[]

: 2005.11

[] 2010

2005.08

[] 2004

[] Modern Casting, American Foundry Society, 2004.12

[]

[] 2001

[] 2002

[] 1999

[] 2002

[10] 2001

[11] JFSincJapan Foundry Society, Inc.

[12] 2002

[13]

[14] 2002

[15] :

2006.05

[16] Giesserei-Literatuschau, VDG-DOK

[17] Quitie, Foundary Institute of the Chinese Mechanaical Engineering

70

Socuety

[18] Foundry Management & Technology, Penton/IPC

[19] Annual Statistical Report, American Iron Steel Institute

71

Kim Min

1955 12

1974

1978

1978

2004200612

2006_VRF_424_hyousi2006_VRF_424_hazimeni2006_VRF_424_012006_VRF_424_022006_VRF_424_03