Stainless Foundry News
How a Short Domestic Supply Chain Saves on Long-Term Costs
How a Short Domestic Supply Chain Saves on Long-Term Costs It’s an age-old question for original equipment manufacturers (OEMs) – are the cost savings from offshore outsourcing worth the potential supply chain risk? Lower cost regions and countries can seem appealing from a profit margin standpoint. But in our experience, the longer the supply chain, [...]
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High Specification Inspection Cell Investment Creates 3 Key Benefits
High Specification Inspection Cell Investment Creates 3 Key Benefits The volume of high specification work at Stainless Foundry & Engineering (SF&E) has continuously increased. So much so, that high specification nondestructive testing (NDT) was creating a bottleneck in SF&E’s newly improved commercial production line, which prides itself on 4-6-week lead times. The solution, up until [...]
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Expertise in Nuclear & NAVSEA
Wisconsin Foundry - Experts in Nuclear & NAVSEA Stainless Foundry & Engineering (SF&E) has been producing cast and machined components for the nuclear and military industries for over 70 years. Our foundry and technical engineering staff have expertise in sea, land, and air applications. We pair high specifications required for military and nuclear applications with [...]
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Can Your Foundry Weld This? SF&E Can.
Can Your Foundry Weld This? SF&E Can. Stainless Foundry & Engineering, Inc. (SF&E) casts over 250 alloys. When pouring that many materials, from time to time, we are required to perform repair welds to remove surface casting defects. Initially, we always attempt to blend and grind surfaces to meet customer contract requirements. However, we cannot [...]
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CASE STUDY: Partnership Streamlines Production for Hydro-Thermal
SF&E Partnership Streamlines Production for Hydro-Thermal Production can only be as smooth as a facility’s material flow. For Hydro-Thermal, the global leader in the development and manufacturing of Hydroheaters, production cannot be interrupted. When working with suppliers, product quality and delivery time are paramount – especially when it comes to one critical part. The diffuser [...]
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PHOTO STORY: SF&E Machining
In-House Machining Solution If you’re paying extra freight costs to ship castings from foundries to machine shops, or having quality struggles uncovering defects after machining, a foundry with in-house machining capabilities could be your solution. Stainless Foundry & Engineering (SF&E) has been machining castings since the mid-1980s. Having a fully dedicated off-site facility, owned and [...]
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Modern Casting Features SF&E Careful Customer Contract Review
Careful Customer Contract Review - Modern Casting In March 2021, American Foundry Society's issue of Modern Casting highlighted the importance of careful customer contract review and quality engineering at Stainless Foundry & Engineering (SF&E). Director of Quality, Mike Porfilio, oversees a team of contract review specialists from diverse professional backgrounds, making sure each element of [...]
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First-of-its-Kind Antimicrobial Stainless Steel
Steel Formulated With 3PRE-Activated Molybdenum Renders A First-of-its-Kind Antimicrobial Stainless Steel Advancing Medical Innovations (AMI) announced earlier this month that its client, Performance Compounds Inside (PCI), has made historic advancements in metallurgy with its 3PRE Technology, a novel and proprietary process of activating antimicrobial properties. PCI's first use of its 3PRE Technology is with molybdenum, [...]
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Schutte & Koerting Chooses SF&E Bronze for Quality, Consistency
Schutte & Koerting Chooses SF&E Bronze for Quality, Consistency Schutte & Koerting (S&K) has more than a century of experience in the design and manufacture of steam jet vacuum systems, steam jet heaters, exhausters and compressors, scrubber systems, desuperheaters, thermocompressors, eductors and syphons, ejectors, and valves. S&K designs both standard product and custom equipment, working [...]
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Bronze is Back – SF&E Dusts off 75 Years of Knowledge to Meet Growing Demand
Bronze is Back – SF&E Dusts off 75 Years of Knowledge to Meet Growing Demand When Stainless Foundry & Engineering opened its doors 75 years ago, bronze was one of our core competencies. SF&E worked with multiple military and commercial customers to pour non-ferrous propellers, various pump components, and split case pumps, among other parts. [...]
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PHOTO STORY: BRONZE ALLOYS
More than Stainless Steel: Casting with Bronze Alloys at SF&E Stainless Foundry & Engineering (SF&E) has been producing cast brass and bronze alloys since the 1970s. Within the past year, we have ramped up volume production and equipment investments to meet a growing need. In particular, SF&E has been working with commercial, pressure-retaining, and Naval [...]
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SF&E Improves Castability and Production Timeline for Complex Impeller
SF&E Improves Castability and Production Timeline for Complex Impeller Workmanship, lead times, and dependability are common qualities any manufacturer looks for when selecting parts producers. But when the part is a custom-made, complex impeller for an industrial pump that needs to run continuously, the necessity of these qualities becomes non-negotiable. A Stainless Foundry & Engineering [...]
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Justin Chamberlin Joins Stainless Foundry & Engineering as Technical Director
Justin Chamberlin Joins Stainless Foundry & Engineering as Technical Director Addition of Technical Director will Support Expansion in Foundry Capabilities Milwaukee, Wisconsin – November 19, 2020 – Stainless Foundry & Engineering today announced that Justin Chamberlin has joined the company as Technical Director. In this role, Chamberlin will oversee melting operations, process control, metallurgy, and [...]
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Restructured, Revitalized, Re-Invigorated
Restructured, Revitalized, Re-Invigorated. The Latest News & Updates from Stainless Foundry & Engineering Stainless Foundry & Engineering's (SF&E) President & CEO, Jim Stachowiak, sat down with Manufacturing in Focus Magazine to share the company's latest news and updates about restructuring, the COVID-19 affects on the foundry, the future of manufacturing, and more. A [...]
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Is Your Foundry Partner Adhering to Governmental Purchasing Requirements?
Is Your Foundry Partner Adhering to Governmental Purchasing Requirements? By Michael Porfilio, Director of Quality and Engineering NDE Level III, Certified Lead Nuclear Auditor To function in the modern, industrialized manufacturing environment, business and quality systems require controls with formal guidelines and good practices. This is especially true when working in government purchasing. [...]
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Non-destructive Testing Usages in the Foundry
Non-destructive Testing Usages in the Foundry The casting for a large, closed impeller manufactured by Stainless Foundry & Engineering (SF&E) has a final ship weight of 2,500 pounds. It is a nuclear service part that was produced at a high specification. In order to leave the foundry, the impeller must pass some critical acceptance criteria. [...]
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The Anatomy of a Pour: SF&E Takes on High-Chrome Iron Casting
The Anatomy of a Pour: SF&E Takes on High-Chrome Iron Casting Stainless Foundry & Engineering (SF&E) is nearing the end of a multi-phase, multi-year operations throughput improvement project. The goal: maximum optimization for an above-and-beyond customer experience. Production efficiency efforts have focused on reducing lead times for commercial sand and investment castings, as well as [...]
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Shrinkage and Gas. How to Eliminate These Common Casting Defects
Shrinkage and Gas. How to Eliminate These Common Casting Defects. When castings have openings, cavities, porous sections, and similar defects on the internal or external surface, it is often called porosity. It is generally due to shrinkage or gas as the casting cools. Both are caused by very different sources. Identifying and eliminating the source [...]
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How SF&E is Cutting Lead Times – Again.
How SF&E is cutting lead times – Again. In 2019, Stainless Foundry & Engineering announced that halfway through its multi-year initiative to overhaul sand and investment foundry operations, we had already achieved lead times between 5 and 7 weeks. Now, we are nearing the end of the Throughput Improvement Project, and are achieving – and [...]
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Steel Founders’ Society of America Recognizes Robert Uitz as Master Founder
Robert Uitz Recognized as Master Founder Robert (Bob) Uitz, Quality Assurance Welding Program Coordinator at Stainless Foundry & Engineering (SF&E), has been recognized by the Steel Founders’ Society of America as a Master Founder and the newest member of the Steel Founders’ Society of America Guild. This artisan honor is the highest level of recognition [...]
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Worth the Risk? 4 Critical Questions to Ask Before Working with a New Foundry.
There are many reasons why original equipment manufacturers (OEMs) question their relationship with an existing foundry partner, from inconsistent quality to ineffective communication. But there is typically only one reason they continue to work with the foundry anyway – the risk of uncertainty. We don’t deny that moving to a new foundry is a [...]
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Business Update to Our Customers and Business Partners amid COVID-19
Dear Valued Customer, Future Customer, and Business Partner, Stainless Foundry & Engineering, Inc. has been operating daily and responding to all customer requests in a timely manner, pouring & delivering successful complex castings, in over 250 alloys, in record lead times. We are highly committed to keeping our customers, employees, business partners, and [...]
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SF&E Pours Largest Nuclear Impeller in its History
SF&E Pours Largest Nuclear Impeller in Its History! We poured the largest impeller in the history of our company. Utilizing AOD ingot, we melted and cast 6,000 pounds of CA6NM martensitic stainless steel. The reputation of Stainless Foundry & Engineering (SF&E) was built on being an industry leader in manufacturing all styles of impellers. Historically [...]
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How a Short Supply Chain Saves on Long-term Costs
How a Short Supply Chain Saves on Long-term Costs It’s an age-old question for original equipment manufacturers (OEMs) – are the cost savings from offshore outsourcing worth the potential supply chain risk? Lower cost regions and countries can seem appealing from a profit margin standpoint. But in our experience, the longer the supply chain, the [...]
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COVID-19 – Update from our President & CEO
COVID-19 - Update from our President & CEO As we all come together to slow the spread of COVID-19 while keeping critical business operating, we want to share with all our Customers, Business, and Community Partners that Stainless Foundry & Engineering, Inc. has been deemed an essential business according to the U.S. Department of Homeland [...]
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Investment Casting Vs Sand Casting: Differences and Advantages
Investment Casting Vs Sand Casting: Differences and Advantages Investment casting and sand casting are reliable, cost-effective, quality manufacturing processes that allow for flexibility in budgets, timelines, and design. The pattern used to make casting molds lasts through thousands of impressions and years of use, producing the exact same measurements every time. Patterns also are easily replicable when [...]
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Why Responsiveness is an Industry Game-Changer
Why Responsiveness is an Industry Game-Changer If you asked a Stainless Foundry & Engineering (SF&E) customer six years ago about the company’s responsiveness, they might have said it was minimal. Or, more likely, they would have said it was “as expected.” Metal manufacturers have historically operated under the reputation that customers get what they get [...]
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Can Castings be Welded?
Can Castings be Welded? The world of fusion welding has effected many industries and fabrication opportunities worldwide. Countless industrial items are assembled using a vast number of different welding techniques governed by numerous rules, codes and norms. Casting upgrade welding is a very specialised series of operations. The casting process offers a unique opportunity as [...]
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“Going above and beyond to reduce cost”- a Gen Z view
"Going above and beyond to reduce cost"- a Gen Z engineer's view Anthony Geiger, Foundry Engineer at Stainless Foundry & Engineering, Inc., is part of the up and coming generation of enthusiastic young metalcasters who will take the industry into the future. He has worked for Stainless Foundry since mid-2018. When you ask him if [...]
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Three Competitive Advantages to Inventory Stocking
Three Competitive Advantages to Inventory Stocking Inventory stocking is a great opportunity for manufacturers to smooth the transition between customer order entry and shipping. Any chance to improve the customer experience will increase the chances the customer stays with you for the long-term. Manufacturers often stock their own inventory on site. But by stocking at [...]
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When to Convert Costly Fabrications into Castings
When to Convert Costly Fabrications into Castings Do your fabricated parts consist of multiple components that need to be cut or machined to size and go through weld fabricating before being machined as one? If so, your parts might be an ideal candidate for a casting. Metal casting is a more cost-effective option for mass [...]
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How SF&E Cut Industry Lead Times in Half
How SF&E Cut Industry Lead Times in Half Stainless Foundry & Engineering (SF&E) is halfway through a multi-year initiative to overhaul our sand and investment foundry processes, employee roles, and equipment. The goal: offer our customers lead times under 4 weeks, which is less than half of the 10-week industry average. The first phase of [...]
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ACCELERATED ONBOARDING SOLVES PUMP PART FAILURES FOR WEIR MINERALS
Accelerated Onboarding Solves Pump Part Failures for WEIR Minerals Stainless Foundry & Engineering addresses client onboarding in 4 ways: Dedicated resources Fast turnaround for quoting and design Specific project plan with weekly client updates Engineering and Quality team involved from the start At Stainless Foundry & Engineering (SF&E), we pride ourselves on our willingness to [...]
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SF&E NOW POURING BRASS AND BRONZE ALLOYS
SF&E now pouring Brass and Bronze Alloys After a ten-year hiatus, Stainless Foundry & Engineering, Inc. is pleased to announce that we are pouring over a dozen brass and bronze alloys for your sand & investment casting needs. Brass alloys, such as Silicon brass (C87500), general-purpose brass (C86500) as well as various other grades are [...]
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WHY CHOOSE METAL CASTING?
Why Choose Metal Casting? Pouring molten metal into a sand, metal, or ceramic mold is one of the most common ways to mass produce a complex part. According to the American Foundry Society, highly engineered metal castings are part of 90 percent of durable goods. And since metal casting is one of the oldest industrial manufacturing [...]
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MCCAFFERY JOINS STAINLESS FOUNDRY & ENGINEERING AS SALES DIRECTOR
McCaffery Joins Stainless Foundry & Engineering as Sales Director McCaffery Joins Stainless Foundry & Engineering as Sales Director Growth in new alloys sparks need for sales and marketing Milwaukee, Wisconsin – April 30, 2019 - Stainless Foundry & Engineering (SF&E) is pleased to announce the addition of Mitch McCaffery as Director of Sales & Marketing. [...]
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STAINLESS FOUNDRY EXPANDS SCOPE OF MATERIALS APPROVAL
Stainless Foundry Expands Scope of Materials Approval Stainless Foundry & Engineering, Inc. (Milwaukee, Wisconsin, USA) as of November 2018 has greatly expanded its scope of approval for materials as assessed for the Pressure Equipment Directive (PEDX) 97/23/EC and 2014/68/EU. Stainless Foundry & Engineering, Inc.’s (SF&E); a high alloy sand and investment foundry, has held a [...]
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Q&A: METALLURGY & ENGINEERING
Q&A: Metallurgy & Engineering Stainless Foundry & Engineering has a reputation for technical expertise that sets them apart from their competition. SF&E has many talented individuals, but two of the leading technical resources that have guided SF&E and her customers to conquer great challenges are Jeanne Wagner (Technical Director and metallurgist) and Florian Wisinski (Director [...]
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NEW 800MM OKUMA MACHINE CENTER
New 800mm Okuma Machine Center Stainless Foundry & Engineering has recently expanded their machining capabilities to impressive dimensions. The 800mm Horizontal Okuma Machining Center will allow SF&E to machine some of their largest casting now in house, saving on lead time, cost and predictability all while utilizing the latest machining technology. Gil Kowalczyk, SF&E Machine [...]
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JEANNE WAGNER PRESENTS AT THE SFSA 2017 CONFERENCE
Jeanne Wagner presents at the SFSA 2017 Conference We are excited to announce that our very own Jeanne Wagner will be attending and presenting at the Steel Founder’s Society of America (SFSA) Technical and Operating (T&O) Conference in Chicago later this week (December 6th-9th). SFSA T&O conference brings together foundries all over North America for [...]
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