Capabilities

With over a century of experience between them, Director of Quality Assurance Maynard Gross and President William Easterly, are the undisputed Masters of Melting.

Their experience spans metals from carbon steel to nickel base, including Monel™ copper-nickel, and all stainless steels. Their expertise extends to Super Duplex Stainless Steels such as CE3MN, CD3MN, CE8MN, CK3MCuN, and Hastelloys (CCW12MU, CW6M, CW2M, CW2MW, and CX2M).

60% of all orders are one piece. Effort Foundry specializes in single-piece orders, usually castings that are large and even complex.

With so much knowledge and experience on staff, Effort is your foundry of choice for melting and pouring all of the difficult alloys.

If it melts, we pour it!

From one pound to one ton, Effort castings are engineered to meet a range of specs and are produced to satisfy our customers’ most exacting requirements.

Specifications

ASTM	AISI
DIN	SAE
Military	ARR
ASME	Customer-specific

Effort’s experienced foundrymen, ASME/Military accredited welders, and other production professionals have vast experience with a number of alloys:

Alloys

Carbon Steel	Iconel®	Iron	Monel
Cu-Ni	Austenitic-, Ferritic-, Martenistic-, and Duplex Stainless Steel	Heat-Resistant	Low Alloy Steel
Manganese Steel	Aluminum Bronze	Nickel Aluminum Bronze	Ultimet

Sampling of Cast Alloys

ASTM A 128 Manganese	A48 CL 25 to CL 50 Iron	150-125	90-60	CA40	CD3MN	CD4MCuN	CE8MN
CF3MN	CD4MCuN	CE8MN	CF3MN	CG3MN	CK3MCuN	CW12MW	CW6MC
CY40	GX3CrNi13-4	HN	HX	LC2	LCC	M35-2	WC1
WCA	105-85	70-30 Cu0Ni	A 536 Ductile Iron	CA6NM	CD3MWCuN	CD6MN	CF3
CF8C	CG8M	CN3MN	CW2M	CX2MV	CZ100	HH	HT
Iconel 601	LC3	M30C	N12MV	WC6	WCB	120-95	80-50
CA5	CB7Cu1	CD4MCu	CE3MN	CF3M	CF8M	CH10	CN7M
CW6M	CX2MW	Ductile Ni-Resist Type 1	HK	HU	Iconel 625	LCB	M35-1
N7M	WC9	WCC

Effort’s in-house heat-treat facilities include furnaces measuring up to 56” x 92” x 42”, suitable for normalizing and tempering any of our alloys. All furnaces are computer-controlled, calibrated, and surveyed to ASME Military standards and nuclear standards.

The new heat treat for all normalization and tempering of carbon, low alloy and martensitic steels has a Nitrogen-enriched atmosphere during all cycles.

The Nitrogen-enriched atmosphere reduces Oxygen present — this drastically reduces oxidation of the castings (scale formation). The end result is much cleaner casting surfaces with little or no oxidation (scale).

Our Fast Track option offers immediate response with deliveries as quick as one week, as needed by the customer.

Other services available include rough- and final machining, passivation, painting, radiography, electroplating, and electropolishing. Together with our in-house capabilities, these services — provided by ISO 9001-approved vendors — make Effort Foundry a true single-source supplier.

Machining Capabilities

Effort’s machining operations are fully ISO certified, and we continue to invest in new technologies to offer our customers rough and finish machining services of castings, patterns, and pattern components. With comprehensive in-house machining services, Effort can validate casting quality, increasing the value we add for customers and dramatically reducing delivery times. Effort’s machining capabilities include 0.0002” tolerances with a growing list of primary machining equipment, including:

Vertical Milling:

Milling, drilling, and tapping

–Fryer MC-10 CNC Vertical Mill – Siemens 840D control

30” x 18” x 22” (XYZ) working area
25hp – 8000rpm CAT40 taper spindle with 20-tool carousel

Vertical Turning:

Turning, drilling, and tapping; milling on top and sides

–Fryer VT-40 CNC Vertical Lathe – Siemens 840D control

40” swing – 38” Stroke
40hp – 1000rpm spindle
8-station live tool turret

Horizontal Turning:

Turning, drilling, and tapping; milling on front/sides

–Fryer ET-40 CNC Horizontal Lathe – Siemens 840D control

40” swing – 60” between centers
30hp – 1000rpm spindle
12-station live tool turret

Horizontal Milling:

Milling, drilling, tapping, with machining on 5 sides in one holding and two rotary devices with full 5-axis capabilities

–Fryer HR-40 CNC Horizontal Mill – Siemens 840D control

40” x 30” x 25” (XYZ) working area
4th and 5th rotary axis
40hp – 6000rpm CAT50 taper spindle with 30-tool carousel

Keyway Cutter:

–Davis Model 15 Keyseater

1/16” to 1-1/2” wide by 12” long keyway cutter

Additional Equipment/Software:

–Faro Edge Measuring Arm

9 ft (2.7m), 7 Axis
Laser Line High Definition Laser Scanner

–Solidworks 2015

3 seats

–Esprit 2015 CAM

3-axis turning and 5-axis milling toolpath creation

–Geomagic Design X

Reverse engineering software by 3D scan data processing for FARO Arm

–FARO CAM2 Smartinspect

Solution for measuring basic geometry and dimensions including 3Dview for FARO Arm