Great Steps Forward –
5th Customer Appreciation Day

Effort Foundry hosted its 5th Customer Appreciation Day.

More than 50 customers attended the event, which started with an early continental breakfast.

The day continued with a 2.5-hour foundry school, led by Vice President of Quality Robert Cheskey, Vice President of Engineering Ed Yandrisevits, and President William Easterly.

Following the school, everyone reconvened in the foundry to witness a live melt/tap/pour of molten steel into a mold.

The attendees then broke into smaller groups for personal, Effort Foundry staff-led tours with detailed descriptions of our operations.

The tour ended with an exhibit by key Effort vendors, including Lab Testing, ExOne, Behler, Solar Atmosphere, and Julian James Advertising Design. Customers even had the opportunity to schedule foundry school events at their own sites.

After lunch and a presentation by our owner, Charlie Hamburg, attendees were invited to an advanced engineering session. This included first-hand introductions to gating, risering, solid modeling, simulation, and 3D/additive manufacturing, led by Ed Yandrisevits, Director of Machining Operations Michael Unmann, and Simulation Engineer Gerard Anthony.

Many thanks to all of those who attended! If you missed the event, our next Customer Appreciation Day will be held in September 2017, so mark your calendars now!

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The Future is here at Effort Foundry!

From new equipment to new processes and some in-house development work we’re especially proud of, Effort Foundry has a number of facility improvements underway.

What it is: Thermo Scientific Niton XRF Analyzer
What it means: The Thermo Scientific Niton XRF Analyzer is the industry standard in positive material identification, and it will enable Effort Foundry to meet its customers’ specifications for positive material certification. The Niton XL2 does not require a ground surface for positive material identification, so there’s no worry about defacing casting surfaces. From rough castings to fully machined castings, the XL2 delivers a positive identification certificate in approximately 20 seconds.

What it is: Nitrogen atmosphere in new normalize/temperature heat-treat oven
What it means: The formation of Deleterious Iron Oxide—also known as “scale”—on castings is a common, unwanted byproduct of the heat treatment process. When scale is present, delivering clean, high-quality castings requires costly grinding and blasting. In December, we began an experiment along with Air Products, introducing inert gas into our current atmospheric furnace. Nitrogen purges the furnace, displacing the oxygen to slow the formation of scale. An oxygen analyzer will monitor O2 levels in the furnace exhaust to optimize Nitrogen usage, while a Brooks 3809 flowmeter will track nitrogen input flow on the inlet side. Preventing the formation of scale will give us the ability to deliver the cleanest possible castings.

What it is: New ArcAir acetylene burning center
What it means: The Arc/burning cell will house three booths with ventilation to ensure that employees are not exposed to any hazardous fumes, as well as adding space and material handling devices. The booths are scheduled to open in April, 2014. The location for the new center has been prepared, including the relocation of a conference room and the digital layout equipment, and the new 30,000 CFM dust collection unit is set for January delivery.

What it is: Dot-matrix casting identification
What it means: Effort is developing a proprietary system to capture and store information relating to the operation-by-operation, start-to-finish processing of each casting. When complete, this will enable customers to check job status at any time from any networked device. The process will automatically track the location of each casting on our shop floor, record the heat it was poured from, the heat-treat batch number, and information relating to the operator name and time taken to perform each step in the casting process.

What it is: New ultrasound equipment
What it means: The addition of this ultrasound equipment will enable Effort to perform new quality checks and capture key data for inspection reports. In this way, we can inspect coarse-grain materials such as Austenitic Stainless Steels and Nickel-based alloys.

Read more about what's new at Effort >

Photos of new equipment

Archived Events

Effort Foundry Hosts Its Third Customer Appreciation Day

Effort Foundry transformed into a learning center for its customers on September 13. … read more>

Effort Secures NIAC Approval

Effort was audited by the NIAC (Nuclear Industry Assessment Committee) in the early summer and received formal approval in October. … read more>

“Model to Metal” in Two Weeks

Effort recently introduced its rapid prototyping process to allow projects to move from “model to metal” in as little as two weeks. … read more>

Effort Foundry Adds Austenitic Manganese Steel to Its Alloy List

Austenitic Manganese Steel is a specialty steel that usually contains approximately 12% manganese. … read more>

Effort Foundry Wins Ben Franklin iXchange Manufacturing Achievement Award

Effort Foundry was recognized last month by the Ben Franklin Technology Partners of Northeastern Pennsylvania (BFTP/NEP) for their manufacturing success. …
read more>

New Casting Dimensional Layout Facility

Effort Foundry’s new QC center now features a Portage Model 60A digital layout machine. … read more >

Foundry School 2009

On September 15, Effort’s plant supervisors hosted the second Foundry School, held at Gaetano’s in Bath, PA. … read more >