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Press Releases

JP Square Joins the Applied Process Sales Team!

Thursday, July 12, 2018

We am pleased to announce JP Square has joined the Applied Process team as
Technical Sales Engineer, effective Monday, July 9, 2018. JP’s primary
responsibilities will be to rapidly increase sales by pursuing opportunities with new and
existing customers and in new markets. JP will represent the entire range of company
services through on-site customer visits, company meetings, attendance at trade
shows, and professional committee work. He will focus on customers in the southern
states including (but not limited to) Arkansas, Kansas, Missouri, Nebraska and Texas
and will report directly to me.

JP is an enthusiastic and results-oriented sales professional, experienced in sales,
project management and customer service. JP brings over 10 years of experience in
sales and business development, and he joins Applied Process following an assignment
with FlightSafety International, a company that provides professional world -class
training to operators of business, regional and commercial aircraft. JP held the position
of Program Manager, where he was responsible for contract review/execution,
production and support for commercial full flight simulators. He expanded new and
existing customer sales base, and initiated effective sales and customer relations
strategies which resulted in an increased profit market share.

JP is a graduate of Oklahoma State University, where he obtained his Bachelor of
Science Degree in Marketing, and a minor in Business Management & Finance. We
anticipate that with his track record for business development and strategic sales
planning, JP will be an integral part of AP’s continued growth moving forward.
Please join us in welcoming JP to Applied Process!

Applied Process Welcomes a New Controller

Thursday, April 19, 2018

We are pleased to announce Josephine (Josie) Miller has joined the Applied Process team as Controller, effective March 19, 2018.  Kathy Oleski, Chief Financial Officer, said "We are very excited that Josie is available to join our team and contribute her skills to our joint success!"

Josie's primary responsibilities will be financial reporting of historical results and forecasting future performance in accordance with established financial accounting and tax rules as well as supporting the execution of management's strategies and goals with her ideas, analyses and problem-solving skills.

Josie has 10 years of experience in public accounting and carries a Certified Public Accounting (CPA) license.  She has spent the last 6 years in industry working as a Controller with financial reporting and tax compliance responsibilities as well as participating in software migrations, implementing internal control systems, and instituting change initiatives for company processes to bring them in compliance with outside requirements.

She is intelligent, experience and a quick learner.  She is also kind and enjoys supporting others to achieve their own personal success.  And we know this because she is not a new comer to AP.  She has in fact audited us a couple of times when she was in public accounting!

Josie received her Bachelor of Business Administration with a focus in Accounting from Walsh College.  She is a mother of two grown children and lives, with her husband, right here in Livonia.

Please join us in welcoming Josie to Applied Process.

Applied Process, Inc., to Open New Plant in Fort Smith, Arkansas

Tuesday, February 13, 2018

Applied Process, Inc., the worldwide leader in austempering heat treatment technology, will expand with a new multi-million-dollar heat treatment plant in Fort Smith, Ark. The 51,000-square-foot plant will house six furnaces and add at least 30 jobs. The plant is expected to be fully operational in the 3rd quarter and will serve customers in the Midwest and South. 

“We are very excited to announce our expansion in Fort Smith,” said Chief Executive Officer Harold Karp. “Record sales performance in 2016 and 2017, combined with a strong new product forecast, make this the right time to expand.” 

Applied Process plants in Livonia, Mich., and Oshkosh, Wis., will remain in operation, serving the automotive, agriculture, aerospace, heavy truck, railroad, mining industries, as well as the military. The Oshkosh facility houses the world’s largest integral quench batch austempering furnace which is capable of austempering parts up to 20,000 lbs. in weight.

“The additional capacity in Fort Smith will allow us to continue to offer industry-leading levels of customer service, quality and turn time,” said Steve Metz, Vice President of Sales and Marketing. “The new facility will allow us to expand into new markets and serve a broader geographic customer base.”

Rusty Rainbolt, who has been with Applied Process for three years on the sales team, will be plant manager. Rainbolt holds bachelor’s degrees in engineering and marketing from Oklahoma State University. “Rusty’s engineering, sales and product experience, along with a strong, experienced leadership team, will ensure a smooth start-up of the new facility,” Karp said.

“Arkansas continues to be a great place where businesses can succeed,” said Governor Asa Hutchinson. “Our dedicated workforce and low business costs help companies like Applied Process reach their highest potential.”

“Working with the Applied Process team on their site search for the past year has been a pleasure. We were able to introduce them to Fort Smith and find the perfect location for their specific needs,” said Tim Allen, President and CEO of the Fort Smith Regional Chamber of Commerce. “The community was a perfect match for the company’s expansion requirements and they will be a great complement to the area.” 

Applied Process, Inc. specializes in the austemper heat treatment process. Compared to more traditional heat treatment methods, austempering makes iron and steel components stronger, tougher, lighter and more wear-resistant. Through technical leadership, an unparalleled number of metallurgical engineers on staff, and dedicated research and development, Applied Process helps customers solve their toughest engineering problems. Visit www.appliedprocess.com for more information.

AP Is More Than Just a "Heat Treater"

Thursday, December 07, 2017

We were recently approached by one of our foundry customers and asked to perform an audit of their operations to assist in their pursuit of excellence and continuous improvement.  Our immediate response was "Definitely! When?" and a date was set for a visit, audit completed and results openly discussed.  Earlier this year we offered casting design inspiration assistance to a customer and it has turned into multiple large opportunities.

Partnering with our customers and growing their knowledge about castings and the austempering process results in cherished "win-win" situations where cost is reduced and product performance is increased.  Allow us to assist by unleashing the deep technical talents that exist within our organization.

ASM George H. Bodeen Award

Monday, November 20, 2017

At the ASM Heat Treating Society- Heat Treat 2017 Show in Columbus, Ohio (last month)- one of our Directors, John R. (Chip) Keough, was honored to receive their George H. Bodeen Award.  Established in 1996, the Bodeen Award, recognizes distinguished and significant contributions to the field of heat treating through leadership, management, or engineering development of substantial commercial impact.

The sentiment on the Keough award reads:

“For advancing business growth by emphasizing fundamental materials knowledge in the heat treating industry and for passionately supporting the next generation of engineers through materials education.”

Chip was overheard saying "I am truly grateful to my peers in the heat treating industry for awarding me with their highest honor, but it represents the hard work of a truly remarkable team, the people of Applied Process, who I have been honored to work with".

With Chip is Steve Kowalski of Kowalski Heat Treat,

Immediate Past President of the ASM Heat Treating Society

Mary McKerrell Joins the Applied Process Team!

Thursday, October 26, 2017

We are pleased to announce Mary McKerrell has joined the Applied Process team as Director of Regional Sales, effective Monday, September 25, 2017. Steve Metz, VP of Sales, said "we are looking forward to Mary’s contributions in her new role, which is commensurate with her vast experience and relationships she has built with numerous auto manufacturers in Michigan".

Mary’s primary responsibilities will be to increase AP’s automotive sales segment by pursuing opportunities with new and existing customers. We are also excited to have Mary contribute to her new role by applying her experience and capabilities in the company’s marketing arena due to her previous extensive background in communications. Mary’s primary sales territory/market will be Michigan.

Mary is a consistent top performer in North American new business automotive tier sales, and has 19 years of automotive experience in technical sales. She brings with her 14 years of direct OEM sales experience with FCA, General Motors, and Ford, and is proficient at identifying strategic opportunities and solutions, while possessing intuitive communication and decision making skills.

Mary joins Applied Process from Acument Global Technologies, a provider of fastening and assembly solutions serving customers worldwide, within the automotive, industrial, construction defense and military industries. Mary held the position of Key Account Manager, where she had the responsibility of managing automotive tier accounts worth over $35 million.

Mary is a graduate of Oakland University in Rochester, MI, where she obtained her Bachelor’s Degree in Communications.  Harold Karp, CEO, said "we anticipate Mary, with her track record for growing and maintaining strong business relationships with customers and industry partners, will be an integral part of AP’s continued growth moving forward".

Please join us in welcoming Mary to Applied Process!

Fab to Cast Conversions Bring Success to AP and Our Customers

Thursday, September 21, 2017

The major area that OEM’s find benefits from the use of ADI is in Fabrication to Casting conversions.  These conversions lower cost, increase performance, and reduce part number counts.  Unfortunately, many engineering teams are short staffed or aren’t fluent in casting design.  For these reason, the Applied Process staff assists customers with numerous casting conversions every year.  Through assisting in the conceptual design and conversion process we can help reduce the time and labor that is involved in a conversion.

Pequea is an Agricultural company who found huge benefits in the Fabrication to Casting Conversion process.  Last year they converted their Inner and Outer Tetter Pivots from two separate welded assemblies that incorporated 40+ individual components to a single Austempered Ductile Iron Casting that can be reversed to form both the Inner and Outer pivot parts.  This is a reduction of 47 part numbers that they no longer make, order, or inventory.  This conversion equated to a huge cost savings, improved product consistency and increased performance.

If you have a troublesome fabrication or a part that you feel might make a good casting conversion, don’t hesitate to contact your local sales person.  We would be happy to help you achieve success like the example shown above!


New Sales Records & thoughts on Driving Sales Growth

Thursday, September 07, 2017

2017 has been a dynamic year with a soft start and a consistent build to our record months in May and June.  At the same time, we have honed our schedule management to achieve record high on-time delivery while maintaining our expected level of the highest quality in the industry.  Agriculture and Heavy Truck have led the way with double digit percentage gains both in historical business along with new product releases.  ‘Seeds’ (time and effort) planted between two and four years ago are now flourishing and we are reaping the benefit of assisting our customers in producing lower cost, lightweight parts with higher performance utilizing Austempered Ductile Iron and Steel.

Growing sales is a priority in almost every business and Applied Process has a unique recipe to accomplish this.  Our focus is perfection in austempering and assisting our customers in the conversion of parts to the process with the best overall value.  Educating our customers and providing assistance with conceptual designs are the foundation of our sales process.  Give us a call, we are happy to provide education and design inspiration at your facility or ours.

AP University - Master of ADI

Thursday, August 31, 2017

Just around the corner on September 26 and 27 we will be conducting our "coveted" AP University session "Master of ADI".  This two-day training session provides design engineers, technicians and purchasing folks with essential information regarding the production of ductile iron, design of castings, a deep dive into the austempering process and finishes up at Joyworks Studio where students get hands-on experience in a state of the art, small scale foundry that is used for both prototyping and education.  This program provides the essential tools for the design or conversion of parts using austempered ductile iron (ADI).  The class takes place September 26 and 27 at our Livonia, MI facility and there are a few spots available.  Join the 250+ graduates of this class and sign up by visiting www.appliedprocess.com/ap-university or contacting your sales manager for additional information.


Thursday, August 24, 2017

On Monday, August 21, 2017, a total solar eclipse, frequently referred to as the "Great American Eclipse", was visible within a band across the entire contiguous United States passing from the Pacific to the Atlantic coasts.  A solar eclipse occurs when the Moon passes between the Earth and the Sun, thereby totally or partly obscuring the image of the Sun for a viewer on Earth.  The path brought 80.96% coverage of the sun to southeastern Michigan.   The employees of AP took a few minutes out of the work day to watch the sun disappear.

The next solar eclipse to happen on April 8, 2024 will bring 99.77% coverage of the sun to southeastern Michigan.




Thursday, August 10, 2017

Whether hoping to find a fresh start, a better job, or a new career direction, job seekers will find exciting opportunities at this job fair.  Stop in before 6pm to see if we are a fit for you.


Monday, August 07, 2017


Our success is a direct reflection of our dynamic team, and because our team is our most important asset, we're committed to making AP a great place to work!  

Stop in to AP Westshore on Thursday, August 10th for Job Fair from 9am until 6pm.  We have full and part time openings for Furnace Operators.  We will have on the spot interviews, training provided, no previous experience necessary.  There will be snacks and refreshments and all attendees will have a chance to enter a drawing to win prizes.


A Message From Our CEO

Thursday, August 03, 2017

I hope this post finds everyone enjoying the summer!  After a cool start we have had a few really good weather weeks in Michigan!

Our business has continued to strengthen as the year has progressed.  After a strong finish to the first quarter, we achieved new sales records in both May and June!  We are experiencing continued strength in our core markets and are having good success closing new business.

I am excited to announce the addition of Wayne Simpson to our management team as plant manager of our Livonia facility.  Wayne comes to AP with 25+ years of engineering and manufacturing leadership experience.  Wayne spent the last 18 years with the Jackson Michigan Gerdau Steel Producing Mill in various roles from Senior Project Engineer to Rolling Mill Manager.   Wayne has a Bachelor of Science in Electrical Engineering from the University of Michigan.

As I mentioned in the April issue of the Hostile Duck Digest, we are focused on strengthening our operational systems and processes.  Our new on-time shipping tracking system is working well providing us with clear visibility of committed ship dates.  I am proud to say that as of the writing of this article, we are 100% on time with our shipments in July!  We are also implementing new processes and systems aimed at improving manufacturing flow in the factories.  This new process will improve turn time, create a robust continuous improvement process and “unleash” additional capacity.   

Mike Krause Promoted to Director of Business Systems and Infrastructure

Thursday, July 27, 2017

We are pleased to announce the promotion of Mike Krause to Director of Business Systems and Infrastructure for Applied Process, Inc., effective June 5, 2017. Mike has been working with AP for almost 2 years, and has been instrumental to the development, implementation and conversion of several sales, operational and financial reporting systems along with providing analysis of process data that has enabled us to better understand our pricing and cost structures. 

In his new role, Mike will be joining the leadership team and will be tasked with strengthening and improving data integrity, information flow and integration of systems throughout the company. 

Mike is a graduate from Michigan State University, where he earned his Bachelor’s Degree in Finance, and he has over 13 years of experience thriving in fast-paced environments with short deadlines while managing multiple priorities.

Mike will have one direct report – Andrew Parsons (IT Helpdesk Support Technician), and will continue to integrate with all our functional departments within the company to ensure ongoing operational excellence.

Please join us in congratulating Mike on his promotion, and wish him continued success with AP!

Andrew Parsons to Man the IT Helpdesk at AP

Wednesday, July 12, 2017

We am pleased to announce Andrew Parsons joined the Applied Process team permanently as our IT Helpdesk Support Technician on May 15, 2017. Andrew has been working with Applied Process on a contract basis since September 2016. Andrew’s primary responsibilities will be to effectively handle customer IT support issues, complaints, and questions, while keeping in mind the company’s overall customer satisfaction. Andrew will be tasked with providing technical assistance and support for various computer systems, software and hardware, and will maintain regular performance of company computer systems.

Andrew has a variety of technical skills and abilities, including diagnosing IT issues, several years of management experience, and computer repairs on software and hardware. Andrew also has experience with various vendor networking implementations and troubleshooting, performing maintenance and upgrades, and overseeing information systems management and security. 

Andrew joins Applied Process following almost ten years working with Canton Computers, where he advanced through multiple positions. His most recent position with Canton Computers was as IT Representative.

Michael Krause, Director of Business Systems & Infrastructure says "We are confident that Andrew will be an integral part of AP’s continued growth, so please join me in welcoming him to Applied Process!"

We're Buildling A High Performing Sales Team

Thursday, June 29, 2017

We would like to announce that Tony Geyman joined the Applied Process team as Technical Sales Engineer October 10, 2016. Tony’s primary responsibilities are to rapidly increase sales by pursuing opportunities with new or existing customers and in new markets. Tony represents the entire range of company products and services through on-site customer visits, company meetings, attendance at trade shows, and professional committee work. His primary territory is Wisconsin, Illinois, Minnesota, and Iowa, and he will report directly to Steve Metz, VP of Sales.

Tony brings over 25 years of foundry and sales experience to his role, and joined Applied Process following an assignment with Badger Alloys in Milwaukee, WI, where he held the position of Strategic Account Manager. This position required Tony to manage and direct the worldwide sales and marketing program, while supporting existing customers, and developing new accounts and market diversification.

Tony is a graduate of St. Norbert College in DePere, WI, where he obtained his Bachelor’s Degree in Communications and Marketing, and a minor in Business. Steve Metz says "with Tony's track record for supporting customers and prospecting/closing new customer leads, he will be an integral part of AP’s continued growth moving forward".


There's A New Plant Manager at AP

Friday, June 23, 2017

We are pleased to announce Wayne Simpson has joined the AP team as Plant Manager of our Livonia Plant.  Wayne's primary responsibilities will be to manager day-to-day operations and facilities manager, along with general supervision of all phases of plant operations.  

Wayne is an experienced engineering and manufacturing leader with over 25 years of experience in industrial manufacturing.  He has  leadership experience in electrical engineering, production and maintenance management, budget accountability and lean manufacturing.  Wayne has multiple areas of expertise including engineering, strategic planning, team building, project management, staff development, and profitability improvement.  Harold Karp, CEO says "Wayne is an experienced manager who leads by example and has strong communication skills and relationship building with internal and external customers".

Wayne joins Applied Process following an assignment with Gerdau in Jackson, MI - one of hte largest suppliers of specialty long steel in the world.  Wayne held the position of Rolling Mill Manager, where he was responsible for supervising a 3-shift operation, as well as process improvement, cost reduction and quality management.

Wayne has a Bachelor's of Science Degree in Electrical Engineering from the University of Michigan, Dearborn.

Steven Sumner, VP of Operations says "We anticipate Wayne will be an integral part of AP's continued growth moving forward and we are excited to have him on board".

Please join me in welcoming Wayne to the AP team!

Biljana Trujillo Joins the AP Team

Thursday, June 15, 2017

We are pleased to announce Biljana Trujillo (pronounced Bil-ya-na) has joined the Applied Process team as Controller. Biljana’s primary responsibilities will be to aid in further advancement of sound and practical accounting systems, policies and procedures that will contribute to decision-making while satisfying our requirements for compliance with financial and tax authorities. Biljana will be responsible for enhancing our planning and forecasting processes, as well as identifying and implementing creative solutions to reach the company’s financial goals.

Biljana is a well-rounded, hands-on finance manager with experience in developing and implementing continuous improvements in business practices using in depth analysis and operational understanding. She has proven abilities in combining technical accounting knowledge with strong information systems management and works hard to collaborate with employees in different departments to work through business transactions and strategies.

Biljana joins Applied Process following ten years as Director of Accounting and Administration with American Surgical Centers, a management and consulting company for free-standing surgical centers and specialty practices in multiple states. She had the responsibility of all financial reporting, capital and investment planning, tax compliance, treasury, and legal administration for nine reporting entities. Prior to that, she worked at one of the largest zinc alloy suppliers in North America and a steel supplier where she gained her earliest experience in both invoicing and purchasing.  Kathy Oleski, CFO says "We are very excited that Billie will be able to relate her first-hand experience to so many of the members of our team!" 

Biljana received her Bachelor of Science in Accounting from Oakland University, and is a Certified Public Accountant, licensed in Michigan.

Harold Karp, President says "We are confident that Biljana will be an integral part of AP’s continued growth".   

Please join us in welcoming Billie to Applied Process!


Ductile Iron Society Annual Meeting

Monday, June 05, 2017

The Ductile Iron Society held it's 2017 Annual Meeting on May 31-June 2, 2017 at the Marriott Chattanooga Downtown Hotel in Chattanooga, TN.  The schedule consisted of technical sessions that ranged in topic from advanced ductile iron research to practical applications of foundry processes.  There was a plant tour of Waupaca's Etowah foundry.  Our own Kathy Hayrynen, PhD, FASM, VP of Rearch & Development  and Angella Sell, Rearch & Deveopment Engineer attended the event.

Students Compete at Science and Engineering Fair

Thursday, May 25, 2017

The 2017 Science and Engineering Fair of Metropolitan Detroit (SEFMD) was held on Wednesday, March 15, 2017 at Cobo Hall in Detroit. Celebrating its 60th year, SEFMD had 2000 students from 125 middle and high schools prepare and present their research projects to over 500 professionals. The American Society of Materials (ASM) had volunteers who judged those projects. AP’s Angella Sell, Reserach & Development Engineer,  was one of those volunteers. The projects were judged based upon the creation, development, and application of materials. The fair is divided into a Senior Division (grades 9-12) and a Junior Division (grades 6-8).

The First Place Award in the Senior Division was given to Frosilda Pushani and Veronica Marougail, seniors at the Macomb Mathematics Science Technology Center. Their research centered upon the separation of silver nanoparticles to be used in antibacterial compounds. David Oates won the First Place Award in the Junior Division. David is an eighth-grader at Douglass Academy. His research focused on examining the effect of different concentrations of sand on the strength of concrete.

AP University – Master of ADI

Thursday, May 18, 2017

We just finished up a session of our ‘coveted’ AP University that we have started to call ‘Master of ADI’.  This two-day training session provides design engineers and technical folks with essential information regarding the production of ductile iron, design of castings, and a deep dive into the austempering process.  It finishes up at Joyworks Studio where students get hands-on in a state of the art, small scale foundry that is used for both prototyping and education.  This program provides the essential tools for the design or conversion of parts using austempered ductile iron (ADI). 

The next class takes place September 26, 27 at our Livonia, MI facility and there are  spots available.  Join the 300+ graduates of this class and sign up by visiting www.appliedprocess.com/ap-university or contact your Sales Manager for additional information. 

Students watch a ductile iron pour at Joyworks Studio

Keegan O'Bannon from Urick Ductile Solutions provides an overview

of the Additive Manufacturing revolution



Applied Process Quarterly Sales & R&D Summit - The Duck is Stronger than Ever

Thursday, May 11, 2017

For two days the Applied Process Sales and R&D teams met to discuss opportunities for growth and scientific advancement with our direct and OEM customers.  At the end of the event Steve Metz, Applied Processes Vice President of Sales summarized that “These two teams are strong in their own rights, but working together we are an unbeatable force in providing lighter, stronger, wear resistant austempered steel and ADI components to our customers.”  During the event a technology roadmap was developed that includes both customer requests as well as ‘new to the world’ research that Dr. Kathy Hayrynen and her team are working on to advance the science of austempering and expand material performance.  Dr. Kathy commented that “Our recently commissioned R&D test furnace will allow us to expeditiously run material evaluations and understand how to further push the capabilities of our already best-in-class UBQA production furnaces.” 

“This team has rallied around a refreshed sales and marketing strategy that focuses on our core strengths.  Combined with our growth trajectory and unparalleled technical R&D expertise there are great things on the horizon for Applied Process” commented CEO Harold Karp.

Finally, an Economic Tailwind

Thursday, May 04, 2017

Over the first quarter of 2017, travels have taken the Applied Process Sales team into many customers, both OEM's and Tiers.  On a macro scale, the winds have shifted and manufacturing activity is improving, most notably in several sectors which have been stagnant for many years.  Backlogs are improving and many foundries are commenting that 2017 is shaping up to be a good year inf the current trends continue.  We are optimistic for an even stronger finish to 2017 as we see a wave of fresh ADI conversions coming into production.

This economic strength is showing as our AP Westshore and Monster parts facilities located in Oshkosh, WI had a record setting month in March.  Our team pulled together and managed the demand by stepping up and volunteering to work extra hours to maintain our high levels of customer satisfaction in terms of delivery and quality.

AFS Sustaining Member Night

Thursday, April 20, 2017

Applied Process and 33 other companies were recognized as sustaining members at the American Society of Materials Detroit Chapter Meeting on March 13, 2017. Applied Process has been a sustaining member of ASM since 1990. Representatives of the Sustaining Member companies recognized at the meeting from left to right are: Mike Blazejewski (Duboi-Heatbath/Park Metallurgical), Kae Trojanowski (RTI Laboratories), Mark Harper (Dinsmore and Shohl), Angella Sell (Applied Process), Chris Ebert (Element Materials), and Tony Coppola (GM Research).

Jon Walczak Joins the Applied Process Team!

Thursday, April 13, 2017

We are pleased to announce Jon Walczak has joined the Applied Process team as Plant Manager of our Oshkosh plant, effective April 4, 2017.  Jon's primary responsibilities will be to manager day-to-day operations and facilities management, along with general supervision of all phases of plant operation including:  production, quality control maintenance, and shipping & receiving.  Jon will also be responsible for assisting in the recruiting, hiring, and training of plant personnel, and facility up-keep and capital improvements.

Jon is a highly motivated leader with strong production and supply chain experience.  He enjoys leading teams to deliver objectives, and believes in continuous improvement to help drive production excellence and strong business performance.  Jon has a passion for safety in the workplace and facilitates employee involvement initiatives to strengthen the company work environment.  Jon has multiple areas of expertise including team building, logistics, Lean training, and business strategy.  Jon has also managed many cost improvement projects to help eliminate waste, and he enjoys working as a team - seeing everyone's efforts translate to successful business performance!

Jon joins AP following an assignment with Pioneer Metal Finishing, a company offering the widest array of metal finishing services since 1945.  Jon held the position of Plant Manger, where he had the responsibility of driving business and team growth, along with overseeing the safety programs, financial success, and overall communication with internal and external customers and suppliers.

Steven Sumner, VP of Operations says "we anticipate Jon will excel at achieving business success through people and process excellence.  He will be an integral part of AP's continued growth moving forward and are excited to have him on board".  

Please join in welcoming Jon to Applied Process!

More Than Just a Heat Treater

Thursday, April 06, 2017

While reflecting upon our success of the last twelve months in the face of strong economic headwinds, it becomes evident the reason we were successful is the strong relationship we have with our customers and the value our services provided.  The end product is a part which has been perfectly austempered, marquenched, or CarboAustemperedTM.  However, our education and design assistance is clearly a competitive advantage in helping our customers reduce total cost, lightweight, and improve part performance.  To assist in this, our team of sales engineers and six metallurgists/materials engineers stand at the ready to help in the development process.  We invite you to attend our newly improved Applied Process University happening May 16 & 17 in Livonia, MI.  For more information, please email Cindy Duman for more info at cduman@appliedprocess.com. In addition, Applied Process offers education and design assistant to our customers through other training offerings.  Please contact Steve Metz at smetz@appliedprocess.com for more information.

Sales Team Expands

Thursday, March 30, 2017

We are pleased to announce Jeffrey Pallitto joined the Applied Process team as Technical Sales Engineer on February 13, 2017.  Jeff's primary responsibilities will be to rapidly increase sales by pursuing opportunities with new and existing customers and in new markets.  Jeff will represent the entire range of company products and services through on-site customer visits, company meetings, attendance at trade shows, and professional committee work.  His primary territory will be Pennsylvania and Ohio and he will report to Steve Metz, VP of Sales.

Jeff is a technical sales leader with a proven track record in global business development, building strategic alliances, and new product development.  Jeff brings over 25 years of domestic and international success in specialty metal industry experience, and his emphasis has been primarily focused on solution selling through material applications.

Jeff joins Applied Process following an assignment with United Hydrogen, a bulk hydrogen producer, serving a multitude of customers in the rapidly expanding hydrogen economy.  Jeff held the position of Business Development Manager, where he had the responsibility of the upstart and development of two new divisions of the company.

Jeff is a graduate of the University of Pittsburg, where he obtained his Bachelor's Degree in Economics, and a minor in Business Administration.  Steve Metz says "we anticipate Jeff, with his track record for business development and strategic sales planning, will be an integral part of AP's continued growth moving forward"

Please join us in welcoming Jeff to Applied Process!

Livonia, MI Achieves Prestigious Nadcap Certification

Thursday, March 23, 2017

At Applied Process, perfect quality and consistency of our austempering and marquench heat treatments have always been one of our key competitive advantages.  In November of 2016 our continued operational excellence was confirmed when we were awarded Nadcap certification, which allows us to heat treat components that are used in the aerospace industry.

Though our quality procedures in place prior to this certification were best in class, the discipline and requirements of Nadcap inspired us to further improve our already robust systems.  Through the leadership of Mark Fore, Quality and Manufacturing Engineer, this work and subsequent certification has further improved the technical service and quality that all of our customers receive.

ConExpo 2017

Thursday, March 16, 2017

ConExpo 2017 was one of the largest and most optimistic shows that AP has attended in quite some time.  The show covered over 2.6 Million square feet of exhibit space and attendance jumped by nearly 16% over the record crowd at the last ConExpo (in 2014).  The true optimization in the market was shown by a record number of equipment purchases made during the 5 day show.  /Areas/Custom/ContentFiles/3-16 ConExpo 2017 Airial Highlighted View.jpg

For Applied Process, this was one of the most supplier friendly and target rich environments for casting conversions that we have seen in recent years.  Tony Geyman and Rusty Rainbolt attended the show for AP, during their three days at the show they visited with 40+ OEMs who were interested in our company following up after the show to work on casting conversions to improve performance and/or reduce overall component cost.  Our sales team will be working hard over the next few months to make many of these Austempered Ductile Iron conversion concepts become reality.  /Areas/Custom/ContentFiles/3-16 ConExpo.JPG

Good News in R&D

Tuesday, March 14, 2017

We are pleased to announce the promotion of Dr. Kathy Hayrynen to Vice President - Research & Development of Applied Process, Inc. effective March 1, 2017. In her 22 years as Director of R&D at AP, Kathy has been a major contributor to the advanced technology position we enjoy in our markets as well as the growth and success of our business.    

Dr. Kathy received her Bachelor’s, Master’s and PhD Degrees in Metallurgical Engineering from Michigan Technological University (MTU). She became a member of the American Foundry Society (AFS) in 1987 and was a Foundry Educational Foundation (FEF) scholarship recipient. Dr. Kathy has been very active on AFS technical committees for 25 years, and she has served as Chair of the Cast Iron Division and the Ductile Iron Research Committee, and has been a member of the Division Council since 2010. Dr. Kathy has been continually active with the Detroit AFS and ASM chapters over the years, and serves on the MTU external advisory board. She has authored over 50 technical papers (winning numerous AFS “Best Paper” awards) and given numerous lectures at industry and technical association events.

Harold Karp, CEO of Applied Process says "We are proud to have Dr. Kathy on our leadership team, as she publically represents the technical leadership we promote in our core values, and works tirelessly to grow and improve austempering in our industry groups and our company & customers." 

Dr. Kathy will continue to lead the R&D team as well as the technology and product development initiatives of AP. She will also integrate with the commercial and operations teams in pursuit of commercial growth and operational excellence.

Please join us in congratulating Dr. Kathy on her promotion, and wish her continued success with AP!

FEF College Industry Conference

Monday, November 28, 2016

Congrats to Connor Rittman awarded the Keith Millis Scholarship at the FEF College Industry Conference. Connor is a University of Michigan Senior majoring in Materials Science and Engineering and is graduating this spring.  Connor  was a Joyworks intern for one year.   AP is a supporter of the FEF and numerous current employees were, at one time, FEF scholars.

FEF is the Foundry Educational Foundation. Their mission statement is as follows: The Foundry Educational Foundation strengthens the metal casting industry by supporting unique partnerships among students, educators and industry, helping today’s students become tomorrow’s leaders.

One of the ways that FEF accomplishes its mission is to annually hold the College Industry Conference in Chicago, IL. The CIC is an opportunity for student delegates, key professors, industry executives, and university administrators to interact and facilitate the sharing of job opportunities and to connect students to potential employers in the industry. Speakers share their experiences in the metal casting industry and student delegates get a chance to interact and ask questions. Scholarships are also presented during Friday’s luncheon. FEF scholarships are offered currently at 19 colleges and universities in North America.

Many leading foundry people and university professors are former FEF scholarship recipients. For this reason Applied Process is a proud corporate contributor to FEF. 

Welcoming our new CEO, Harold Karp

Wednesday, November 23, 2016

Applied Process is pleased to announce the appointment of its new CEO, Harold M. Karp. Harold is a seasoned business leader, having successfully led four businesses over the past 30 years. Harold joins Applied Process from his most recent position as president/CEO and board director at Tecumseh Products Company of Ann Arbor, Mich., a leading global manufacturer of compressors and related products. He has a great deal of experience in business growth, new product development, operational improvement, quality/continuous improvement, and accretive acquisition.

Harold’s unique business management perspective comes from serving in various roles, such as CEO, president/COO and corporate controller, as well as from holding senior roles in sales, marketing, operations, business planning and product development.

“I am honored and excited to join Applied Process,” said Harold. “I look forward to guiding the growth of this leading technology company.”
Harold is a team-oriented leader who ensures the business offers the “best in class” value to partners. His focus at Applied Process will be to grow the business through continued investment and by building upon the company’s position as the worldwide leader in Austempering technology. In addition, Harold will lead Applied Process into offering new services to ensure customers have a competitive advantage in their markets.

Congrats to AP's Mark Fore and Connor Montgomery!

Thursday, October 13, 2016

Congrats to AP’s Quality Engineer Mark Fore and Process Engineer Connor Montgomery (not pictured) on recently graduating from the Young Executive Series Management Training Program through M.T.I. last week in Nashville, TN. Over the course of the past year, conferences were held in Austin, Philadelphia, Chicago and Nashville.  The YES program combines in class learning, experiential exercises, online learning and plant tours to help maximize your abilities in leadership, strategy and building high performing teams.  Check out the link which features all of the 28 MTI Graduates ~ https://www.heattreat.net/blogs/tom-morrison/2016/10/27/mti-graduates-another-28-execs-in-yes-program

Congrats to all! 





DIS World Conference - Approaching Fast!

Monday, August 08, 2016

Its not too early to start making arrangements for the DIS World Conference on Austempered Ductile Iron in October.   The show will take place in Atlanta, Georgia this year.  For more information check out the link below.  We hope you think about joining us!





Applied Process featured in Modern Casting magazine

Wednesday, March 23, 2016

Applied Process was featured in Modern Casting Magazine for helping Urick Foundry with a bearing house conversion.  To learn more check out the article in Modern Casting Magazine featured on page 48.  

Link to article: http://content.yudu.com/web/y5b2/0A1snzj/ModernCastingFeb2016/html/index.html?page=50


Welcome Aboard Mark Fore

Friday, January 29, 2016

Effective December 14th, 2015. Mark Fore has been named to the role of Quality & Manufacturing Engineer.  Mark’s primary responsibilities will be to facilitate all product of process quality-related activities for the AP Family of Companies.

Mark has extensive experience in project management, customer relations, logistics, continuous improvement, technical contractual management and over 8 years of quality systems knowledge to this new role.

Mark joins Applied Process following an assignment with TE Connectivity in Fairview, NC, where he most recently held the position of Reliability Laboratory Manager, and was tasked with scheduling and managing all final acceptance testing, validation/qualification testing, and military specification maintenance reporting for aerospace, defesnse, and marine facilities.

Mark is a graduate from Ashford University in Clinton, IA, where he obtained his Bachelor’s Degree in Organization Management, and a Master’s Degree in Project Management. Christopher Bixler, Principal Process Engineer of Applied Process says " We anticipate Mark, with his track record for improving both quality and customer relations, will be an integral part of AP’s continued priority to provide the highest quality austempering services available to our customers .”

We welcome Mark to Applied Process!



Welcome Aboard Mike Krause

Friday, January 08, 2016

Effective November 2, 2015.  Mike Krause has been named to the role of Manager of Financial Forecasting & Analytics. Mike's primary responsibilities will be to develop and implement accounting systems, policies and procedures which will contribute to financial decision making.

Mike is a passionate finance professional with over 12 years of finance and accounting experience.

Mike joins Applied Process following an assignment with ForeSee Results where he advanced through various roles during his tenure.  He most recently held a position of Financial Planning & Analysis Manager.

Mike is a graduate from Michigan State University, where he earned his Bachelor's Degree in Finance. Kathy Oleski CFO of Applied Process says, “We anticipate Mike will be an integral part of AP, with his high aptitude for thinking beyond the task at hand, and evaluating processes in an effort to make them more streamlined and efficient.".

Please join us in welcoming Mike to Applied Process!



FEF College Industry Conference

Tuesday, December 08, 2015

AP's Director Chip Keough attended this years FEF Conference.  FEF is the Foundry Educational Foundation. Their mission statement is as follows: The Foundry Educational Foundation strengthens the metal casting industry by supporting unique partnerships among students, educators and industry, helping today’s students become tomorrow’s leaders.

One of the ways that FEF accomplishes its mission is to annually hold the College Industry Conference in Chicago, IL. The CIC is an opportunity for student delegates, key professors, industry executives, and university administrators to interact and facilitate the sharing of job opportunities and to connect students to potential employers in the industry. Speakers share their experiences in the metal casting industry and student delegates get a chance to interact and ask questions. Scholarships are also presented during Friday’s luncheon. FEF scholarships are offered currently at 19 colleges and universities in North America.

Many leading foundry people and university professors are former FEF scholarship recipients. For this reason Applied Process is a proud corporate contributor to FEF. Several of our employees were FEF students and we are proud to give back and continue to recruit from this event. It is also an opportunity for AP to stay in contact with the Key Professors for future senior design projects and research opportunities.  This year U of M will be represented by Tedd Sheets Jr., a UoM senior in Materials Science and Engineering who is also a Joyworks engineering intern.

Congratulations to the scholarship recipients! And to all the student delegates: we can’t wait to see you in the industry soon!


Thursday, October 15, 2015

Effective September 8, 2015, Alisa Patel joined Applied Process as the Director of Human Resources.

We recognize that this position is of great importance to the AP Companies as we look to the future.  We conducted a very thorough and extensive search over the past few months.   Alisa is a goal-oriented Human Resources professional with over 10 years of valuable experience and proven achievements in managing HR functions.  John Wagner, President of Applied Process stated "Alisa's drive to improve our culture is a welcome addition to the team".

She joins AP from an assignment with Clear Rate Communications, Inc. where she served as the Human Resources Manager for five years.  Her credentials are extensive and we welcome her to the team.


Case Study: Circle Gear & Machine Company and Pequea Machine Inc.

Thursday, October 08, 2015

Many years ago an Amish farmer located along the Pequea Creek in the Pequea Valley of Gordonville, Lancaster County, PA wanted to dry his hay quicker.  He started to build a fluffer tedder and, as they say, the rest is history.

Our friends from Pequea Machine Inc. are featured in the September 2015 issue of Gear Solutions Magazine for a recent gear conversion.  http://www.gearsolutions.com/article/detail/6588/case-study-circle-gear-and-machine-company-and-pequea-machine-inc

Angella Sell Joins the Research and Development Team

Thursday, October 08, 2015

Effective August 24, 2015, Angella Sell joined Applied Process as a Research & Development Engineer.  Her primary responsibilities will be to provide metallurgical support to our plants, customers, licensees, sales team and research efforts.

Angella joins Applied Process following previous assignments with Ellwood Engineered Castings, in Hubbard OH, and Columbiana Foundry Company, in Columbiana OH, as a Metallurgical Engineer.

Angella earned a Bachelor's of Science degree in Metallurgical Engineering from the University of Missouri - Rolla, and a Master's of Science degree in Metallurgical Engineering from the Missouri University of Science & Technology.

Kathy Hayrynen, PhD, FASM, Director of Research & Research stated "We expect great things from Angella, and are thrilled to have her on our team".  Please join us in welcoming Angella to Applied Process.


Effects of Microstructure and Strength on Wear Performance in Rough Milling of Austempered Ductile Iron

Tuesday, September 29, 2015

The machinability of various grades of austempered ductile iron (ADI) has been investigated for rough milling operations. ADI 900, ADI 1050 and ADI 1200 grades were commercially produced, commercially heat treated and machined under controlled conditions using coated carbide inserts with coolant in the laboratory. The milling performance of the various grades was compared to that of AISI/SAE 4340 with similar hardness. In this study, machinability characteristics relative to wear rate (ISO 8688-2) and machining forces were measured and related to initial microstructure and properties. These preliminary results have been used to establish initial rough milling machining guidelines for machining ADI with coated carbide milling inserts.

Click on the link below for the full article.


Hodge Foundry and Applied Process Monster Parts Division Produce Record-Setting Casting

Thursday, September 24, 2015

The people at Hodge Foundry (Greenville, PA) are experts at making heavy section ductile iron.  Earlier this year our friends at Hodge Foundry poured the heaviest and thickest Austempered Ductile Iron (ADI) casting ever made in North America.  It was austempered at the Applied Process Monster Parts Division in Oshkosh, WI. 

Nodularity and nodule count are important in ADI production, and it is not easy getting optimal numbers in heavy section parts.  We analyzed a cast 5”x5”x12” test block that served as surrogate to sectioning a casting.  The results were impressive: 162 nodules per mm2 and 80%+ nodularity on a 5” section size.  Those measurements were made in the center of the sample. 

The photo shows the microstructure at 100X.

Stay tuned for more metallurgical innovation!

Applied Process Conducts Purchasing of Ferrous Heat Treatment Seminar

Wednesday, September 23, 2015

The Applied Process family of companies today conducted the second annual AP University Purchasing of Ferrous Heat Treatment seminar.

More than 30 people attended the class on-site at Applied Process in Livonia, Michigan.  The group consisted mainly of Purchasing professionals, but there were also a few engineers in attendance. The class covered key aspects in the purchasing role when it comes to buying a variety of heat treatment services.  The instructors discussed such processes as austempering, induction hardening, carbonitriding, annealing, and others. The goal of the class is to help buyers to get exactly what they are ordering at the best possible deal.

The class was conducted by Applied Process personnel and our friends from Specialty Steel Treating, Inc., AjaxTOCCO Magnethermic, and Bluewater Thermal Solutions.

AP's John Keough is shown conducting a session at the AP

University Purchasing of Ferrour Heat Treatment seminar


Tuesday, August 04, 2015

Applied Process is pleased to announce that Kristen Knaffle will assume the new role of Sales and Marketing Associate.

Kristen joins Applied Process from an assignment with Tim Horton's Regional Offices in Marketing and Central Michigan Life as a Public Relations Intern.

Kristen earned a BA in Integrative Public Relations, with a minor in Public Affairs from Central Michigan University.  Vasko Popovski, Director of Sales & Marketing stated "we anticipate Kristen will bring an energetic and focused approach to our Sales efforts".

We welcome Kristen to Applied Process.


THE BRIGHT WORLD OF METALS...Growing the Pie Worldwide

Thursday, June 18, 2015

THE BRIGHT WORLD OF METALS....Growing the Pie Worldwide

The four global trade fairs in the heart of Europe - GIFA, METEC, THERMPROCESS and NEWCAST.  Together in Dusseldorf this week the quartet of technology trade fairs present products and services, technologies and current trends for the global markets of tomorrow.

Growing the Pie Worldwide are Andy Chen, President of Austemper Process (Jilin) Technology Inc.  John R. (Chip) Keough, Director of Applied Process, Inc. and Vasko Popovski, Director of Sales & Marketing for Applied Process, Inc..

Phil Patterson Joins Technical Sales Group

Wednesday, June 03, 2015

Effective May 11, 2015, Phil Patterson has assumed the role of Technical Sales Engineer for the Applied Process companies.  His efforts will be focused on Growing the Pie in the American Midwest.

Phil joins Applied Process with solid experience as a product manager with Dotson Iron Castings in Mankato, MN.  Phil also has experience in lead generation, tooling design and sales.

Phil also brings a background in LEAN Manufacturing, Value Stream Mapping and Front Line Leadership.  We expect Phil will hit the ground running with his Sales efforts.  He will be based out of Mankato, MN where he will connect in person with OEMs, foundries, and machine shops.

The AP team intends to Grow the Pie to new levels, and Phil will be a critical part of that enterprise.

Connor Montgomery Joins AP Westshore as Manufacturing Process Engineer

Wednesday, May 20, 2015

Effective March 16, 2015, Connor Montgomery joined the AP Westshore team as a Manufacturing Process Engineer. 

Connor’s primary responsibilities include improving overall plant equipment and efficiency, safety, environment compliance, and quality systems. He will also assist customers in design or conversion of parts in austempered ductile iron or steel.  Connor will also assist in the design, specification, bidding and building of equipment for all Applied Process facilities.

Connor joins Applied Process from an assignment at Neenah Foundry where he served as melt foreman for the facility. 
Connor has a Bachelor’s Degree in Industrial Technology from University of Wisconsin Platteville.  We expect that he will be a great addition to the AP Westshore team.

Rusty Rainbolt Joins Technical Sales Group

Wednesday, May 13, 2015

On March 30, 2015, Rusty Rainbolt assumed the role of Technical Sales Engineer for the Applied Process companies.  His efforts will be focused on Growing the Pie in the American Midwest.

Rusty joins Applied Process from an assignment at Farrar Corporation of Manhattan, KS.  While employed with Farrar, he performed multiple leadership roles, including most recently as the Operations Manager for the Machining facility.  Rusty also has extensive experience in casting sales.

Rusty earned a BS in Engineering and Marketing from Oklahoma State University.  We expect that Rusty will hit the ground running with a strong technical approach to his Sales efforts.  He will be based out of Clay Center, KS where he will connect in person with OEMs, foundries, and machine shops.

Vasko Popovski, Director of Sales and Marketing stated "The AP team intends to Grow the Pie to new levels, and Rusty will be a critical part of that enterprise".  We welcome Rusty to Applied Process.




AFS Best Paper Award Cast Iron Division

Wednesday, May 06, 2015

It is a pleasure to tell you that the Cast Iron Division of the American Foundry Society Division Council has selected a paper written by Kathy Hayrynen, PhD (Applied Process, Inc.), Ricardo Aristizabal (University of Antioquia), Robin Foley, John Griffin and Charles Monroe (University of Alabama at Birmingham) to receive 2015 Best Paper Award .  The paper receiveing the award is Austemperability of Intercritically Austempered Ductile Iron (14-070).  The award was presented as part of the AFS Recognition Luncheon on April 21, 2015 at the 119th Metalcasting Congress in Columbus, Ohio.  Congratulations to all.


AP’s Henry Frear in Modern Casting magazine

Tuesday, December 09, 2014

Be sure to check out page 78 of the November 2014 Modern Casting magazine.  You can see it here.  We are very proud of Henry and his team’s efforts.  You can be sure that we will try hard to get some ADI on next year’s car!

ASM International President Visits Applied Process

Thursday, November 20, 2014

On November 10th  ASM International President Dr. Sunniva Collins presented at the Detroit Chapter dinner meeting.  On the 11th we were honored to host her at Applied Process, the University of Michigan and Joyworks.  The photo attached was taken at UoM.  The young lady in blue in the front row is Elayne Thomas, President of the Michigan Materials Society (the student organization).  The fellow in the gray sport coat is Manish Mehta, Chairman of the Detroit Chapter of ASM International.  Dr. Collins is in the white jacket in the front row.  Others of interest in the picture include Joyworks intern, Crystal Chen in the second row. (Crystal will be a Foundry Educational Foundation delegate at the College Industry Conference in Chicago on November 20 and 21).  UoM MSE Department Chair Amit Misra in the maroon sweater vest and Professor John Allison far right.  The rest of the people in the picture are students who are active with with UoM’s MMS.

ASM Detroit Chapter Names Scholarships

Wednesday, October 08, 2014

ASM Detroit Chapter Awards Six Teacher Scholars

Including Two Named for Kathy Hayrynen and Peg Jones

The ASM-Detroit Chapter is proud to announce our inaugural class of Teacher Scholars:

Pamela Opolsky (Academy of International Studies) . .Kathy Hayrynen Scholar
Wanda Bryant (Henderson Academy, Detroit) . . . . . .Peggy Jones Scholar
Judy Armstrong-Hall (Larson MS, Troy) . . . . . . . .Detroit Chapter Scholar
Stephen Barry (Harper Creek HS, Battle Creek) . . . .Detroit Chapter Scholar
Jaime Hilliard (MMSTC, Warren) . . . . . . . . . . . Detroit Chapter Scholar
Michelle Sauter-Portelli (Central Academy, Ann Arbor)Detroit Chapter Scholar


Each summer, over 15 teachers attend the week-long Materials Camp for Teachers in Ann Arbor. Through laboratory demonstrations that be replicated in classrooms, the teachers are given the information to bring the world of Materials Science to their students.

In order to aid the teachers in demonstrating Materials Science to their students, the idea of a Scholar Award was created. The Award consists of a $250.00 grant to the teacher to be used for the purchase of equipment and supplies needed to perform the experiments. In order to be eligible, the teacher attended the Materials Camp and then wrote a short paragraph detailing how they would use the money to promote STEM education in the

The Chapter was fortunate to have 12 high-quality applications submitted. After much consideration and discussion, six of the applicants were chosen. Their intended uses of the grants ranged from the purchase of a digital microscope to be used in viewing dendrite formation to the purchase of small rolling mill to study recrystallization and grain growth.

The Chapter is also proud to name two of the Scholarships for Kathy Hayrynen and Peg Jones. Both ladies have greatly contributed to the formation, organization, and operation of the Materials Camp for Teachers in Ann Arbor for many years; they have ensured that the Camp is a model for ASM. In recognition of their extra effort and time given, the named Scholars are presented to the two teachers that are most determined to aid their students despite local resource and funding limitations.

The ASM Detroit Chapter is proud of its Scholars and of our chapter

Profile of a Volunteer

Wednesday, August 20, 2014

Profile of a Volunteer
Kathy Hayrynen, FASM
Director of Research & Development
Applied Process Inc.

Mentors make a difference. Kathy Hayrynen feels fortunate she had strong mentors at every stage of her career—most of them ASM fellows.  She met her first mentor, Don Mikkola, in her senior year of high school during a research internship at Michigan Tech. “Later, he gave me a membership application to ASM and said ‘you need to pursue this organization, it will be important in your career!’” 

With her interest in metallurgy, Hayrynen earned a Ph.D. at Michigan Tech and joined Applied Process Inc., specializing in heat treatment of metals, specifically austempering of cast iron and steel. She is responsible for day-to-day operations of the R&D department and is liaison to multiple technical organizations.  Kathy chaired the Detroit ASM chapter, served on the Awards Policy committee at the national level, and was named a 2006 ASM Fellow. Asked why she is a loyal volunteer, Kathy explains, “ASM helps me stay current and gives me the opportunity to give back to the next generation.” 

Most of her volunteer time is spent organizing the summer camp for high school and middle school teachers at the University of Michigan in Ann Arbor. “What I like best is the look on a teacher’s face when they learn something hands-on to take back and engage their students,” says Kathy. “We do more good this way than working one-on-one with a student. When you do something for a teacher, they influence hundreds.” 

Kathy engages next-generation engineers by getting them involved with students closer to their own age, in activities such as judging science fairs. “People need a voice and guidance.

They are waiting for mentors and there’s nothing greater than seeing them get that.” ASM has served that role in Kathy’s life, allowing her to give back as her own mentors did for her. “My career path—and my success—would never have happened without my involvement in ASM."

Reprinted from AM&P Magazine, April 2014-Vol 174 No. 4

Applied Process Takes on Majority Interest Partner

Monday, August 18, 2014

Effective today, Applied Process Inc. (Livonia, Michigan, USA) has announced that it has taken on a majority interest equity partner, High Street Capital of Chicago, Illinois, USA (www.highstreetcapital.com).  High Street is a private equity firm with a track record of partnering with, and growing, successful companies since 1997.  High Street Capital is investing in AP as they believe in the management, the people and the business.   

John Keough, AP’s founder, stated, “We are pleased that we have a strong partner in High Street Capital going forward.  My family and I will maintain a significant capital interest in the business. I will continue as a director and will be, as always, actively engaged in the growth of the business and the profitable conversion of components from one material/process combination to a better, faster, cheaper one”. 

John Wagner, AP’s President, commented, “Austempering offers our customers a cost effective way to obtain stronger, lighter and less expensive parts.  With High Street Capital as our new capital partner, we have the added resources to expand our capabilities, continue to improve upon our already industry-leading service, and to expand geographically.”

Dick McClain, (an HSC Principal) stated that, “The High Street Capital partners are looking forward to working with the world-class leadership team and employees at AP to continue AP’s mission “to grow the pie for Austempering”.

In 1984, Applied Process Inc. was incorporated as a stand-alone division of Atmosphere Group in Wixom, Michigan, USA, with John R. (Chip) Keough as President.  In 1986 Applied Process moved to their current Livonia, Michigan address.  In 1993 Mr. Keough spun AP out of Atmosphere Group and (with his wife and children) became 100% owners.  As demand for AP’s Austemper-focused technologies and services grew, AP expanded “to the other side of the lake” and commissioned AP Westshore in Oshkosh, Wisconsin, USA. AP’s most recent addition has been the Monster Parts™ plant in Oshkosh. 

In between, AP established plants and licensees in Australia, England, Canada, China and India.  Each has yielded organizational experience and contributed to AP’s growing international network of industrial and technical contacts and resources, and to AP’s reputation as a world-wide leader in Austempering technology.  AP’s technologies, facilities and people are, demonstrably, the best in the business.  For more information visit: www.appliedprocess.com

AP University May 2014

Tuesday, May 20, 2014

Another session of AP University is underway. 

AP University trains attendees in the design and manufacture of ductile iron and Austempered Ductile Iron (ADI) castings and components.

Training consists of 2 days of classroom instruction from experienced and qualified instructors, several of whom have taught at the college level.  It also includes two plant tours.  The first takes students through the original Applied Process plant in Livonia, MI.  The second tour takes place at the Joyworks Studio in Ann Arbor, MI, where students will watch actual ductile iron production.

Joyworks Happy to Add Customer Support

Wednesday, May 14, 2014

Heat-treater Applied Process expanded its educational metalcasting studio to reduce conversion and prototyping times for metalcasters and OEMs.

This month's edition of Modern Casting features the story.  Click on the link below to see the full article.


Dr. Kathy Hayrynen Presents the Prestigious Hoyt Memorial Lecture

Wednesday, May 07, 2014

The American Foundry Society’s Hoyt Memorial Lecture was established in 1938 and has been a highlight of every AFS Metal Casting Congress since then.  The chosen lecturer is selected for his/her contributions to the metal casting industry.  This year our own Dr. Kathy Hayrynen presented the lecture “It’s All About Marketing”.  Dr. Kathy engaged a standing-room-only crowd with her call for those of us in the metal casting and related industries to evolve from being “order takers” to “order makers”.  She presented a unique angle on the marketing of metal castings; not just  selling product, but the sustained marketing of the industry to our customers, our employees and our various communities.  To mirror National Manufacturing Day she proposed “4 Metal Casting Day” and regional activities to educate and inform the industrial base and consumers about metal castings.  She pointed out that the metal casting industry is the largest recycling industry and, by definition, a green industry; far from the public perception.  She challenged the industry to support R&D and calculated that if the North American foundry industry were to re-invest just 1% of sales in R&D it would represent $347 million per year in metal casting research……….research that will improve cast metal products and processes and expand our future markets.  As Past-President of the Foundry Educational Foundation, she found it curious that only 7% of metal casting companies support FEF, the organization that identifies and grooms students for jobs in the industry.  She concluded by emphasizing the positive aspects and strengths of the metal casting industry and urged her audience to embrace and promote the industry to our customers, our employees and our communities.

Kathy is Applied Process’ Director of Research and Development.  She received her bachelor’s, master’s and PhD degrees in Metallurgical Engineering from Michigan Technological University.  She became a member of AFS in 1987 and was an FEF scholarship recipient.  She did post-doctoral work at MTU prior to joining AP in 1995.  Kathy has been very active  on AFS technical committees for 25 years.  She has served as Chair of the Cast Iron Division and the Ductile Iron Research Committee and has been a member of the Division Council since 2010.  She has been continually active with the Detroit AFS and ASM chapters over the years and serves on the MTU external advisory board.  She has authored over 45 technical papers and given scores of lectures at industry and technical association events. Amongst other awards, she has won the 2003 AFS Ray H. Witt Award and the 2004 AFS Award of Scientific Merit.  She has also won numerous AFS “Best Paper” awards.

We are honored (and proud) to have Dr. Kathy on our AP team.  She publically represents the technical leadership we espouse in our core values and works tirelessly to grow and improve our industry, our communities and our company.  Please congratulate her for this significant recognition.

Hostile Duck Visits the Climax Molybdenum Mine

Wednesday, April 30, 2014

Hostile Duck made a cameo appearance at the Climax Molybdenum Mine, the world’s largest known body of molybdenite ore.  The Climax Mine straddles the Continental Divide in Colorado at the Fremont Pass 11,318 feet above sea level.  Moly is an important alloying element in heavier section Hostile Duck Iron parts, so the ever inquisitive Hostile, stopped to have a look.

AFS/FEF Student Technology Contest

Monday, April 28, 2014

Brandon Wervey is a Manufacturing Technology student at the University of Wisconsin-Platteville.  He received an award for winning the 2014 AFS/FEF Student Technology Contest at the FEF Board of Directors meeting at UW Platteville on April 23, 2014. His research project was "Development of CADI Grinding Balls."

Both Henry Frear and Kathy Hayrynen of Applied Process Technologies Division provided technical support of this project.

118th Metalcasting Congress - Hoyt Memorial Lecture

Monday, April 07, 2014

Don't miss Kathy Hayrynen, PhD, FASM give the Hoyt Memorial Lecture at the 118th Metalcasting Congress this Friday.

The Hoyt Memorial Lecture was established in 1938 and has been a highlight of every Metalcasting Congress for 75 years. 

HOYT MEMORIAL LECTURE: It's All About Marketing
In order for the metalcasting industry to survive and thrive, it must be able to market itself and the products it produces to its customers, the next generation of employees and the communities in which its facilities reside. Unfortunately, this has not always been done in a consistent fashion across the industry. Hoyt Lecturer Kathy Hayrynen, Applied Process Inc., will discuss the importance of marketing and suggest some actions for our industry to take.

Austempered Ductile Iron Casting Success Stories

Wednesday, March 12, 2014

Applied Process personnel were in attendance at the CONEXPO-CON/AGG show in Las Vegas last week.  There were plenty of opportunities for forward-thinking people to execute casting conversions.  AP’s Henry Frear is shown in these photos with two well-publicized ADI casting success stories.  Contact Applied Process to learn more about lightweighting your components with ADI technology.

John R. (Chip) Keough Presents at a Recent ASM Meeting.

Tuesday, February 18, 2014

Just in from The Monty this morning:

ASM Meeting/Inland Empire Chapter. From Bob Grammer, a well respected rep in the US Northwest US we have this report about a recent ASM meeting. "This photo shows John R. (Chip) Keough, ASM Trustee and  Board Members at an ASM Inland Empire Executive Committee meeting last night, Feb. 12th in Spokane, Washington.  The meeting was held inside a renovated boiler in the old Spokane Steam Plant.  A great restaurant by the way.

Seated Right to left: Cedric Devaney, Past Chair, Hi-Rel Labs;
John Keough, ASM Trustee, Chairman - Applied Process Technologies Livonia, Michigan
Trevor Devaney, Past Chair, President Hi-Rel Labs
Ron Palma, Past Chair, Hi-Rel Labs
Alex Fabrick, Washing State Univ. Materials Advantage Chapter
Ryan McIlvaney, Past Chair, Hi-Rel Labs
Camera man - Yours truly

Later at the full chapter meeting, John Keough gave a very enlightening and entertaining presentation on the properties and applications of Austempered Ductile Iron (ADI).  The main message was that this relatively new material can reduce the weight and dramatically reduce the energy required (and therefore cost) of many automotive, truck and heavy equipment components.  It was an exciting talk to say the least.  We highly recommend John to other ASM chapters who are looking for a great speaker. Attendance at the meeting was 36 including ASM chapter members, 8 students and faculty from Washington State University and visitors from local industry.  On the previous evening the ASMIE chapter held the first of 3 classes on Introduction to Materials to a class of 56 people from industry around the area on the campus of Gonzaga University.  Yes, the Gonzaga with the great basketball team!

Incidentally, a couple of other interesting side points:
1.  John is the brother of Bill Keough, owner of AFC-Holroft. John is also the holder of two engineering degrees - one in Materials Science  and one in Mechanical Engineering.  He is very involved in local Detroit ASM chapter and Materials Advantage activities.
2.  ASM surprised me (Bob Grammer) with a Lifetime Membership Award last night - 40+ years. February 14/2014.

The 2014 Ram 1500 is Motor Trend's 2014 Truck of the Year.

Thursday, February 06, 2014

The 2014 Ram 1500 is Motor Trend's 2014 Truck of the Year.  The engineers at Ram have designed this truck with ADI components.  You can contact your friends at AP to learn more about how ADI can help you to make your designs lighter, stronger, and more wear-resistant.


Foundry Educational Foundation College Industry Conference

Tuesday, February 04, 2014

In December John R. "Chip" Keough presented "Cast Iron IS a High Tech Material-The Road to ADI" at Key Professors meeting.  He represented the University of Michigan at the event and took two students, Ryan Breneman and Chad Kelsey, both AP/Joyworks interns, who are entering the workforce in the spring.

What’s Stronger Than a Polar Vortex?

Monday, February 03, 2014

Seventeen engineers braved the severe winter weather in the Midwest to attend the January 2014 session of AP University, hosted by Applied Process Inc., leaders in austempering technology. AP University is an invitation-only, educational event for engineers hosted twice a year by Applied Process, based in Livonia, Michigan. The AP University session includes classroom lectures and workshops on casting design and metallurgy, and tours of heat treatment and metalcasting sites. The goal of the three-day seminar aims to teach engineers new component design possibilities made possible by working with ductile iron and austempered ductile iron (ADI) castings. The group of attending engineers – some who traveled to Michigan from as far away as Oklahoma and British Columbia – represented various industries, including: heavy truck, agricultural equipment, light vehicle, metalcasting and railroad. By expanding the engineer’s knowledge base, AP University builds opportunities for engineers to explore casting conversions from forgings to fabrications for existing components they design. Classroom lectures at the January session of AP University focused on design possibilities to make components lighter, stronger, more wear-resistant and less costly. Topics included Casting Design, Understanding Test Coupons and Iron Specifications, Introduction to Foundry Processes, Heat Treatment of Ductile Iron, and Machining ADI. With energy savings and fuel economy of high importance for most manufacturers today, this seminar highlighted optimizing component design by using ductile iron castings as a cost-effective tool in lightweighting. The AP University students also toured the Applied Process facility in Livonia, Michigan, to see heat treatment of castings first-hand. The group also visited Joyworks Studio in Ann Arbor, Michigan, to see foundry operations up close, including melting, treatment and pouring of ductile iron. Attendee Jim Kennedy, VP of Engineering from A. Stucki Corporation, said to the AP staff “I really enjoyed the AP University and learned a lot from each of you. Your support and training of your customers is unprecedented and greatly appreciated. I am certain that we will be sending more of our employees to future AP University sessions.” The next session of AP University is in May 2014. For more information about the AP University program, please contact Vasko Popovski at vpopovski@appliedprocess.com." January 28/2014.


AP University graduate Paul Jones send us this photo.

Monday, January 27, 2014

AP University graduate Paul Jones send us this photo of Hostile Duck standing ready on his deck to open a bottle of something cold!

2014 AP University

Monday, January 27, 2014

AP University is a three-day intensive seminar that teaches engineers new ways to fabricate parts that save cost, time, and energy - for the engineer and the consumer.

Henry Frear of Applied Process and Dan Leger of Ditch Witch discuss foundry tooling.


Kevin Fleischmann of the Cast Metals Institute holds a tree of castings.  Kevin is joined by John Keough of Applied Process, Chris Witt of Dotson Iron CAstings, and Jon Deagale of Pacific Rim Engineered Products.






ADI considered for monster gears by American Gear Manufacturers Association

Thursday, December 19, 2013

Imagine a gear nearly 53 feet in diameter, running some of the largest machines in the world. What does it take to make that gear, and what materials are the optimal choice? Justin Lefevre, principal engineer at Joyworks Studio, met with the American Gear Manufacturers Association (AGMA) mill gearing sub-committee to be part of discussions on material standards this October.

The mill gearing sub-committee met in Bocholt, Germany where Siemens (Previously Flender) hosted the committee for the two days of meetings to discuss incorporating Austempered Ductile Iron (ADI) as a gear material into the body of AGMA 6014, the industry standards for rating gears for grinding mill and kiln service.
Inclusion in the ratings will allow more seamless design for ADI girth gears for use on mills and kilns. Siemens and Ferry Capitain provided tours tours of their facilities for the committee after the meetings.

In the picture below, Lefevre stands with members of AGMA's mill gearing 6014 sub-committee at a CNC gear cutting machining center at the Ferry Capitain facility in Hattingen, Germany. The machine in the background is a gear turning/cutting/milling machine capable of manufacturing gears up to 16m (or 52.5 ft.) in diameter.

When life hands you LeMons - Applied Process sales engineer races Chubba Cheddar Enduro in AP-sponsored car

Thursday, December 12, 2013

Henry Frear, Regional Sales Engineer for Applied Process, raced in the LeMons' Chubba Cheddar Enduro race at Road America in Elklhart Lake, Wisconsin in November, in a car sponsored in part by AP. For those who aren't familiar, LeMons is endurance racing for cars costing $500 or less. The beaters of yesteryear, the scraps of sports cars gone bad, the former glorious monsters of the road all live to race another day in this entertaining endurance race contest.

Frear was part of Team Priority Fail (#43), which placed 6th overall in the Class B group, racing their Volkswagen Golf 207 laps in 14.5 hours over two days, covering more than 800 miles. The team consisted of Frear, Nathan Schlawin, Patrick Kluesner, Dan Kaul and Travis Love. Schlawin, Kluesner and Kaul also work in the metal casting industry, representing Metaltek, Magma Foundry Technologies and Signicast respectively.

According to Hooniverse, which covered the race in detail, "When the checkered flag flew to conclude the race Sunday, four cars were still on the lead lap, the only time that’s ever happened." It was also reported that this was the closest race in Class B history as well.

Additional coverage of the race and antics on and off the track can be found on the Car & Driver blog and on the 24 Hours of LeMons Facebook Page and YouTube highlight video.


Pictured (l-r) Nathan Schlawin (Metaltek), Patrick Klausner (Magma Foundry Technologies), Henry Frear (Applied Process), and Dan Kaul (Signicast). Not pictures is Travis Love, Owner/Operator of Yogi Bear's Jellystone Park

Applied Process Chairman John “Chip” Keough Talks About His "Labor of Love" known as Joyworks

Tuesday, November 12, 2013

John "Chip" Keough, Chairman of Applied Process, started Joyworks in 2005 as a private studio for exploring metal casting applications. Shortly thereafter, he began inviting students from the University of Michigan's Materials Science and Engineering program to visit the studio for hands-on laboratory experiences in metal casting. Serving as an adjunct faculty member and Foundry Educational Foundation Key Professor at Michigan, he admits his studio days with the students are a "labor of love" born of his passion for working with metals. Below is a video produced by the college highlighting Joyworks.

To learn more about Joyworks, visit www.joyworksstudio.com.


Dr. Kathy Hayrynen delivers keynote address at the 2013 Keith Millis Symposium on Ductile Cast Iron in Nashville, Tennessee

Thursday, October 31, 2013

Dr. Kathy Hayrynen, Director of Research & Development for Applied Process, delivered the keynote address at the 2013 Keith Millis Symposium on Ductile Cast Iron in Nashville, Tennessee.

The symposium is named after International Nickel researcher Keith Millis, who first discovered ductile iron in 1942 and was largely responsible for first developing the metal for multiple commercial uses.  He was a co-inventor on the first US patent for ductile iron.

Dr. Hayrynen addressed advancements in the metallurgical processing of ductile cast iron since its discovery and its growth in commercial usage, from 440 tons in 1949 to 22.6 million tons in 2010.

She revisited a number of Millis’s own speeches during her address, sharing with symposium attendees what she thought Millis himself might say based on current advances in the industry.

Dr. Hayrynen also challenged the attendees with some important questions.  She highlighted the need for more education for engineers in the multiple uses of ductile cast iron and for more companies to take advantage of promoting ductile cast iron for commercial applications. She asked, “Is your company an order taker or an order maker?”

As leading experts in Austempered Ductile Iron applications, AP works with our customers to find them the best solution for their needs.  This helps us all to become better “order-makers” in the industry.

To read more talks and papers from the AP team of experts, visit our technical library or connect with us directly to allow us help you find the perfect Austempering solution.

Halloween Lunch

Thursday, October 31, 2013

The folks at AP Tech celebrated Halloween with a pot luck lunch.  Everyone had a good time and the worms were yummy!

Athletes Among Us: AP Sponsors Dotson Iron Castings Team at World’s Toughest Mudder Competition

Thursday, October 10, 2013

The World’s Toughest Mudder is an extreme fitness competition that puts the world’s most hardcore “Mudders” - extreme adventure runners - through a grueling 24-hour challenge course. The objective is to complete as many 10-mile laps as possible around the course, which includes such obstacles as mud pits, razor wire fencing, rope walls, fire rings, arctic-temperature water and tunnel obstacles, among others.
Last year, AP sponsored JR Schulte and Tyler Baka of the Dotson Iron Castings “Casting Shadows” team, who finished in the top 500 racers. The duo officially completed 3 laps within the 24-hour time period. The team shot video from their race, available here.
Both JR and Tyler are already busy training for the 2013 competition, taking place November 16 and 17 in Englishtown, NJ. Training is in full swing, and both hit the gym daily and run or bike to work about three miles away.
AP is proud to sponsor these athletes again for the 2013 competition, and we will be cheering on our partners in the foundry industry.  The Dotson Company is looking for additional monetary assistance to help JR and Tyler cover the costs of travel and gear. If you would like to support these athletes during their journey to become the World’s Toughest Mudder, contact Matt Schindle at mschindle@dotson.com.  Good Luck Casting Shadows!

AP and Joyworks Intern Chad Kelsey wins H.H. Harris Scholarship

Thursday, October 03, 2013

Chad Kelsey, the joint AP and Joyworks intern, was recently awarded an H.H. Harris
scholarship of $2,500. The H.H. Harris Foundation was established in the will of Henry Hickman Harris for the purpose of providing scholarships and other forms of educational aid to students and professionals in the metallurgical and casting of metals field who are U.S. citizens. The foundation members meet annually in June to vote for award recipients. Chad is a senior in Materials Science and Engineering at the University of Michigan.

Known among his colleagues as a very capable and thoughtful worker, Chad has used his internship to sharpen his lab and sample prep skills, and has pursued independent study of metal casting subjects related to his internship. Chad has cast everything from aluminum, to gray iron and ductile iron (for Austempering, of course!). AP congratulates Chad on his scholarship and is happy to have him as a member of the team.  

Applied Process Chairman Addressed Michigan Materials Society Lunch on September 13, 2013

Thursday, September 26, 2013

John Keough, Owner and Chairman of Applied Process addressed students at the Michigan Materials Society Lunch at The University of Michigan on Friday, September 13th.  He delivered a talk titled, "Materials Science and Engineering - Doing Good AND Doing Well."  The talk addressed existing examples of the ways materials science applications are helping to solve broader engineering and environmental issues, for the benefit of both scientific progress and humanity.

Mr. Keough also discussed the advantages of membership in technical organizations including Materials Advantage and the American Foundry Society and has offered to pay the first year dues for students interested in pursuing memberships in these organizations.

Mr. Keough also serves as an adjunct professor at the University of Michigan and is the Foundry Educational Foundation (FEF) Key Professor at the university, and will be interviewing students interested specifically in exploring metal casting and experiential and scholarship opportunities provided through FEF.

See You There - AP Speaks to The American Foundry Society, Northeastern Wisconsin Chapter, October 7th

Tuesday, September 24, 2013

Steve Metz, Vice President and Plant Manager – AP Westshore and AP Monster Parts Division will present a talk, “Taking the Alchemy out of Austempered Ductile Iron Production” for the Northeastern Wisconsin Chapter of the American Foundry Society. Metz will address the importance of process control, chemistry and graphite structure in the production of proper ADI. The talk will take place on October 7th at Germania Hall in Menasha, Wisconsin, beginning at 5:30p.m. For more details, visit the web site for the chapter, which can be found here http://www.afsnew.org/afsheader.jpg.  We hope to see you there!

To read more talks and papers from the AP team of experts, visit our technical library.



Athletes Amoung Us: AP Sponsors Sprint Triathlete

Thursday, September 19, 2013

Applied Process is proud to sponsor athletes connected to our family of companies. Marcie from North Canton, OH is our September athlete of the month. She finished in third-place at the Fit Family Series sprint Triathlon in Portage Lakes State Park on September 15. Marcie donned the signature AP logo on her race day kit. If you can’t work with metals all the time, winning medals is the next best thing. Way to go Marcie!

See You There - AP Speaks to The American Foundry Society, Chesapeake Chapter, October 24th

Thursday, September 12, 2013

Vasko Popovski, Director of Sales and Marketing for Applied Process will present a talk, “Good Iron to Great Iron - Foundry Considerations for Austempered Ductile Iron Production” for the Chesapeake Chapter of the American Foundry Society. The talk will take place October 24 at The Bay City Restaurant in Hanover, PA, beginning at 5:30p.m. For more details, visit the Facebook page for the AFS Chesapeake Chapter. We hope to see you there!

To read more talks and papers from the AP team of experts, visit our technical library.


Lucky Duck Benefits From 3D Technology, Just Like Our Customers

Thursday, August 22, 2013

At Applied Process, our company vision centers around being a team of passionate people providing innovative Austempering solutions. We're also known for our feisty Hostile Duck mascot.

So, we saw a lot of parallels when we read the following article in the August issue of Advanced Materials and Processing magazine, published by ASM International. Applied Process has two ASM fellows on our executive team, Dr. Kathy Harynen (2006) and Chip Keough (1998).

One lucky duck named Buttercup with a malformed flipper got a new lease on life through 3D printing technology. Scientists were able to print a new flexible plastic prosthetic flipper to help this duck get back his waddle. The full story is below.

Applied Process uses 3D printing technology to model and build casting molds for parts that require less machining and welding, but still provide the best strength and stamina possible. 

When you have the right materials and the right people, anything is possible.AMP magazine 147077-AUG 2013_selected-pages.pdf

Florida Beaches - Sun, Sand and Hostile Duck?

Thursday, July 18, 2013

We love our customers, and it’s nice to receive updates from their adventures with the Hostile Duck, especially when there is a beach involved!

Tom from Seco Machine in North Canton, Ohio sent us this photo of his AP chair surf-side on the beach in Florida. Usually when we see this much hot sand there is liquid iron around somewhere!

Thanks Tom for the picture. Do you have any of AP’s Hostile Duck gear? Send us a picture like Tom’s and it just might end up in our news highlights

2013 Cast Iron Division Awards

Monday, July 08, 2013

Dr. Kathy Hayrynen was recognized for completing her term as National Chair of the Cast Iron Division for the American Foundry Society at the AFS CastExpo in April.   She is pictured on the left with other Cast Iron Division honorees Chantal Labrecque and Serge Grenier (Rio Tinto), Kevin McMahon (ELKEM) and Lizeth Medina (Donsco).  Congratulations to all!

AP University Back in Session

Friday, May 03, 2013

The Applied Process team already knows the benefits of using ductile iron and Austempered Ductile Iron (ADI) in manufacturing applications. It’s our specialty, but many engineers, designers and buyers we work with know very little about putting it to work for them.

We could rattle off plenty of statistics that show how converting to ductile iron and ADI castings saves thousands in costs (our technical library offers that proof). But, we have learned that in order to get what we do, you need to DO what we do.

Here’s where AP University enters the picture. This May, Applied Process hosted its spring session of AP University, offering three-dozen designers and engineers the chance to learn about and work directly with ductile iron and ADI castings. Attendees represented 16 companies from the heavy truck, agriculture equipment, machining, metalcasting and turf care industries.

During the three-day session, attendees studied the metallurgy of ductile iron, casting design, understanding casting specifications, minimizing casting defects, applications for ADI in gearing, heat treating and casting conversions. Classes were taught by AP’s own team of industry experts and attendees were invited to use the session to troubleshoot for their own clients to find ways to produce stronger, highly wear resistant, cost efficient castings.

The AP University motto, “laborare et gaudendum” - “Work hard and have fun” - captured the overall spirit of the session, where attendees enjoyed the chance to debrief and network at group lunches and dinners after daily lectures and tours.

The final day of AP University included a casting demonstration at Joyworks Studio (www.joyworksstudio.com), the metalworking foundry owned by AP Chairman John Keough. Each attendee took home a Joyworks-cast bottle opener in the shape of the Hostile Duck, AP’s official mascot.

Pictures from the latest session are posted below and you can learn more about working with ductile iron and ADI castings by contacting Vasko Popovskil at vpopovski@appliedprocess.com. Look for the official AP University web site - www.apuniversity.com - coming soon.

Charlie Westfahl and Fred Held of Kuhn/Krause (left and middle) stand alongside Henry Frear of Applied Process outside of Joyworks Studio on the third day of AP University.

AP Chairman John Keough (left) and Colin DeWood of Elyria Foundry (right) show the casting pattern used to make Hostile Duck bottle openers at the most recent session of AP University.

Paul Jones of Waupaca Foundry (right) stands by as Henry Frear from AP (left) prepares to pour molds at Joyworks Studio.

Dave and Tom Seccombe of Seco Machine (left and middle) are shown here with AP’s Justin Lefevre who holds ductile iron castings which are still hot from shakeout.

Rusty Rainbolt of Farrar Corporation stands next to a tree of castings at AP University.

The Applied Process Family of Companies hosted the first-ever session of Applied Process University....

Thursday, January 10, 2013

The Applied Process Family of Companies last week hosted the first-ever session of Applied Process University in Livonia, Michigan. This seminar is a three-day class for engineers on casting design with an emphasis on ductile iron and austempered ductile iron (ADI). Topics also included heat treatment and machining of ADI components as well as foundry processes. Instructors at this seminar were degreed engineers and included AP Director of Research & Development, Kathy L Hayrynen, PhD, FASM.

Thirty-one design engineers traveled to AP University from a diverse mix of industries. This cross-section of American manufacturing included manufacturers of Heavy Trucks, Agricultural Equipment, Rail Equipment, and Light Vehicles.

Attendees at AP University had two days of classroom instruction including a tour of operations at Applied Process. The third day of AP University was at Joyworks Studio (Ann Arbor, MI) where actual ductile iron castings were made.

Are you interested in attending a future session of AP University? If so please contact Applied Process at +1-734-464-8000 and ask for Director of Sales and Marketing Vasko Popovski, PE.


This photo shows AP University instructors Henry Frear, Chad Kelsey, and Justin Lefevre demonstrating a pour of ductile iron at Joyworks Studio.

Drew Sahlstrom of Dotson Iron Castings and AP University instructor Vasko Popovski show a casting tree poured only a short time before.

Applied Process Elevates Vasko Popovski to Director of Sales and Marketing....

Thursday, December 20, 2012

Effective immediately, Vasko Popovski, PE will assume the role of Director of Sales and Marketing for the Applied Process companies.  In addition to the duties of directing our sales efforts, Vasko will now assume the duties in the marketing arena.

Vasko received a Bachelor of Science degree in Metallurgical Engineering and a Bachelor of Arts in Economics from the University of Pittsburgh.  He also has a Master of Arts degree in Technology from Kent State University and is currently working on an MBA from Waynesburg University.  Vasko is a licensed Professional Engineer in Wisconsin, Ohio, and Pennsylvania.  He has published thirteen technical papers in various journals.

He has been with the Company for five years and has over 20 years of industry experience.  He is an active member of the American Foundry Society and serves on three AFS committees.  Vasko also serves on one committee with the Ductile Iron Society.

AP's President, John Wagner, said "I have the utmost confidence that Vasko will be able to guide the corporations' sales and marketing efforts as we continue to grow the pie".

Please congratulate Vasko on this achievement and promotion.

December 12, 2012

Wednesday, December 12, 2012

Recently John Keough traveled to India to visit our licensee Hightemp.  Their production has increased significantly in the past few months and should soon rise to 80% capacity in their line at Pune which was only commissioned in April.

Picture above:  D Gopal, Pratap Ghorpade, Amit Kochar and Narendra Kasar

Applied Process, Technologies Division Announces a new Director of Research and Development....

Friday, November 09, 2012

Applied Process, Technologies Division is pleased to announce that Kathy L. Hayrynen, PhD, FASM will become the Director of Research and Development.  In her new role Kathy will initiate and complete research programs that will distinguish us from our competitors.

Kathy has a BS, MS and PhD in Metallurgical Engineering from Michigan Technological University.  Her graduate work focused on production of ductile iron and ADI.  Following a post-doctoral research position on Ausformed/Austempered Ductile, Kathy joined the AP companies in 1995.

Kathy is well known in the Austempering world having authored and co-authored many papers on ADI and frequently speaks on said topics.  She is the Chair of the Cast Iron Division of AFS, the President of the Foundry Educational Foundation and a member of the External Advisory Board for the Department of Materials Science and Engineering at Michigan Tech.

Kathy has received several industry/academic honors including:  an AFS Award of Scientific Merit, an AFS Ray H. Witt Management Award, 4 best paper awards from the AFS Cast Iron Division, the Ductile Iron Society Annual Award, ASM Fellow, ASM Educational Foundation George Roberts Award and induction into the MSE Academy at Michigan Tech.

Please congratulate Kathy on a well deserved promotion.

Recently released on The Monty....

Thursday, September 20, 2012

Heat Treat Trivia Time.  The "business" of the heat treating business has always fascinated us:  who is the largest, the largest furnace out there, the most furnaces in other words the "business" of the industry.  So let's have a look at a few of the record holders: September 20/2012

8)  The world's largest Integral Quench Atmosphere Batch Furnace?  (How about one designed and built, in a collaborative effort, by Applied Process Inc. and AFC-Holcroft?)

With a salt quench that has working dimensions of 84in x 96in x 56in (2050mm x 2438mm x 1422mm) and a maximum gross load of 20,000 lbs (9,090 kg).


Wednesday, August 22, 2012

A Comparison of Fatigue Properties of Austempered Versus Quenched and Tempered 4340 Steel by John M. Tartaglia and Kathy L. Hayrynen published in the June issue of the Journal of Materials Engineering and Performance.

The paper talks about the study to determine if austempered 4340 steel has a different fatigue resistance compared to quench and tempered 4340 steel with an identical hardness of nominally 45 HRC and an identical yield strength of nominally 1340 MPa.

See the AP Technical Library to download your copy.

FEF Board Approves Dr. Kathy Hayrynen as President

Thursday, June 28, 2012

On May 1, 2012 at the FEF Annual Meeting at Texas State University, Dr. Kathy Hayrynen was elected to serve as the 2012-13 President of the Foundry Educational Foundation.  Kathy has been a member of the board of Directors of FEF since 2007.  She is the Key Contact for FEF for Michigan Technological University, a member of the Education subcommittee and the immediate past Chair of the Employment Resources subcommittee.

Dr. Kathy has served as the Technical Director of the Applied Process family of companies since 1995.

A History of Successful Innovations and Partnerships

Monday, April 09, 2012

The year was 1995 and Steve Metz, then a young foundry engineer, was challenged to develop a replacement power and free conveyor dog for use on one of his manufacturing company’s internal production lines. It was the first of many times Metz would collaborate with Applied Process on product development.

“We could easily produce the casting, but needed to make it strong and wear resistant as well,” Metz said. “About this same time, I had been talking with John Wagner at AP about the benefits Austempered Ductile Iron (ADI). This was the first austempered ductile iron part that we would develop with the new Applied Process facility in Oshkosh, WI, which opened its doors in 1995.”

ADI is a specialty heat-treated material that takes advantage of the near-net shape technology and low cost manufacturability of ductile iron castings to make a high strength, low cost, excellent abrasion-resistant materials. Six grades of ADI are available, depending on the levels of strength, abrasion resistance and toughness required for the product.

Metz explained, “We made the tooling, poured the castings, machined them and then AP Westshore heat treated the part to grade 5 ADI, all very cost-effectively. The parts have operated very effectively over the past 15 years as indicated by the repeat orders by the customer. It stands up to the abrasive conditions of the production operation and has resulted in a piece price reduction of 75 percent. What a great success story!”

As for Metz, after fifteen years working for an AP customer, he spent five years with a company that is a furnace alloy supplier to the Applied Process Group. Recently he joined Applied Process, being named Vice President and Plant Manager of AP Westshore, the same plant he visited in 1995 as a casting designer. “I have come full-circle, and it feels as though destiny has brought me here,” he said.

ADI is used successfully in steel forgings, castings, weldments and aluminum forgings and castings, within the construction and mining, agriculture, automotive, heavy truck and railroad industries. For more information, visit www.appliedprocess.com.

April 2, 2012

Monday, April 02, 2012

Applied Process releases a new YouTube video highlighting Hightemp Furnaces Ltd.
Bangalore, India.


February 21, 2012

Tuesday, February 21, 2012

Advanced crash test dummies often use Austempered steel for their ribs to imitate the flexibility and toughness of the human ribcage (without the breakage).

Applied Process takes delivery of their new Clark Forklift.

Thursday, February 16, 2012

Both Trevor Janas and Jacob King work in the Shipping/Receiving Department at Applied Process "this is a welcome addition to our shipping department" says Trevor and Jacob.   They are charged with keeping order in the department and making sure everything is in it's proper place.

January 30, 2012

Monday, January 30, 2012

APPLIED PROCESS is leading the way with their education efforts.  Watch the latest YouTube video to see "Professor Chip" give a lesson on Austempered Ductile Iron.


January 5, 2012

Thursday, January 05, 2012

Rubber duck delivers components to make hostile duck…the first truck to arrive at APW this morning was carrying a section of the Monster Parts™ furnace. Take a look at the hood ornament....it's a replica of the “Rubber Duck” statues from the 1970’s movie “Convoy”.

A Quality Supervisor at Applied Process Inc., Donny Parker, devised a devilishly clever version of an AP Monster Parts(TM) logo.

Thursday, December 08, 2011

A Quality Supervisor at Applied Process Inc., Donny Parker, devised a devilishly clever version of an AP Monster Parts(TM) logo.

The Foundry Educational Foundation held its annual College Industry Conference in Chicago November 17-18.

Tuesday, November 29, 2011

There were 86 student delegates from FEF affiliated and FEF certified schools all across North America. They were feted by metalcasting industry representatives manning 43 tables at the Industry Information Session. The FEF CIC brings together students with educational and experiential metalcasting backgrounds who have been pre-selected by their FEF Key Professors with metalcasting related businesses in demand of such talent. John (Chip) Keough, CEO of Applied Process Inc. in his role as Adjunct Professor to the University of Michigan Materials Science and Engineering department also serves as the UoM FEF Key Professor. UoM was represented at the FEF CIC by student delegate Demetri Golematis, a senior Mechanical Engineer who has hands-on metal casting experience at Joyworks studio and lab, Austempering and design experience at Applied Process Inc. John and Demetri can be seen in this photo proudly displaying a University of Michigan pennant.

ASM International's Heat Treating Society had their board meeting on Sunday, October 30 at Heat Treat 2011 in Cincinnati, Ohio.

Wednesday, November 02, 2011

This meeting is for incoming and outgoing Board and Committee Chairs.  Pictured below is the entire Heat Treating Society Board.  Notice our very own John Keough in the front row.


Oshkosh, Wisconsin - AP Westshore has a new Vice President/Plant Manager with the addition of Steve Metz to the team.

Friday, October 07, 2011

Steve is a graduate of University of Wisconsin-Milwaukee and holds a BS and MS in Materials Engineering, along with an MBA.

Mr. Metz has 19 years of engineering, product development and manufacturing experience in southeastern Wisconsin.  He spent 14 years with Kohler Company in the foundry and ceramics groups and five years with Castalloy in Waukesha, a supplier of heat resistant alloy to the heat treatment industry.

AP's COO, John Wagner, said "He enjoys learning about and improving processes in a hands-on, inclusive manner and educating the customer about how castings can improve design along with reducing cost and lead-time."

Outside of work, Steve enjoys any mechanical project around the home, cooking, woodworking, biking, running, volunteering with service groups and getting involved in local government.