In the role of Engineer, Primary Metal -VIM Operations at PTC's aerospace casting BU, the individual will play a pivotal role in overseeing and managing the melting and pouring operations. This critical position demands a deep understanding of aerospace casting processes and metallurgical aspects pertaining to melting and pouring operations, along with operational excellence. The individual will be responsible for ensuring the efficient and precise execution of melting operations to meet quality standards and production goals.
Key Responsibilities:
- Coordinating production requirements with the production planning department and the Plant Head, ATL Primary Metals.
- Ensuring product safety and preventing the FOD (foreign object debris) and Counterfeit parts in their concerned area.
- Collaborating closely with the production team, particularly the pre-cast operations team, to verify the readiness of molds for pouring.
- Ensuring that appropriate quantities and grades of raw materials needed for VIM-produced castings are available.
- Ensuring adherence to material preparation processes and appropriate sampling/lab testing; suspending procedures in case of discrepancies and ensuring consultation with the Plant Head of Aerospace Castings.
- Implement quality control measures to ensure that the melted metal meets required specifications and standards.
- Oversee the maintenance and calibration of VIM equipment to minimize downtime and ensure reliable operation.
- Ensuring optimal parameters related to remelting and pouring of feedstock material in the VIM furnace, ensuring optimal vacuum levels, inert gas usage, and maintaining vacuum integrity for near-net-shape component production, followed by managing the HIP process as per method card instructions and controlled cooling in an inert atmosphere.
- Maintaining the Process Control Parameter document, encompassing master heat metal source, ceramic core composition (if used), mold refractory formulation, including prime and backup materials, mold backup material details (weight, thickness, or number of dips), furnace type, atmosphere, charging and melting practices, mold preheat and pouring temperatures, and duration of molten metal in the furnace (hours or minutes).
- Investigating and promptly resolving any issues or deviations in the melting process, minimizing downtime, and adhering to production schedules.
- Approving all production documents or inspection sheets related to melting and pouring operations; Reporting quality issues through the initiation of Non-Conformance Reports (NCR).
- Verifying that metallurgical and mechanical properties align with Test Guidelines and Acceptance criteria for castings produced.
- Ensuring adherence to industry regulations, environmental standards, and safety protocols relevant to melting operations.
- Confirming that all equipment undergoes preventative maintenance as per the plan, to ensure fault-free operation.
- Enforce safety protocols and guidelines to ensure a safe working environment for all personnel involved in VIM operations.
- Efficiently managing resources, such as manpower, raw materials, and energy consumption, to attain production targets and enhance cost-effectiveness.
- Implementing 5S principles in the Ti Cast facility, planning resources and materials accordingly.
Desired Candidate Profile
Education and Certifications:
- Bachelor's degree in Materials Science/Metallurgical Engineering, Production/Mechanical Engineering, or related field.
Experience:
- 2-7 years of proven experience in melting operations in foundries or casting manufacturing operations.
- Experience in the aerospace industry or precision castings industry will be highly preferred.
- Strong hands-on experience of vacuum melting processes, like induction melting and arc melting will be highly preferred.
Technical / Functional Expertise & other competencies:
- Strong understanding of melting processes, including induction melting, vacuum melting, and other relevant techniques.
- Proficient in analyzing and interpreting technical data and specifications related to melting and pouring operations.
- In-depth knowledge of metallurgical principles, specifically related to aerospace casting alloys.
- Familiarity with SPC and related quality control processes and standards in precision casting operations.
- Ability to troubleshoot and resolve technical issues in melting and pouring operations/foundry operations.
- Commitment to safety, environmental stewardship, and regulatory compliance in manufacturing operations.
- Strong leadership and team management skills.
- Effective communication skills for collaboration with cross-functional teams.
