The investment casting engineer will be responsible for new product development, existing product yield improvement, and rework reduction for the business’s investment cast turbine airfoils. Using their experience and statistically reviewed data, the engineer will develop part specific injection dies, tooling, processing parameters, core balance, and dimensional control procedures to manufacture dimensionally conforming castings. This is a high visibility, critical role that requires efficient and accurate verbal and written communication to and from customers and internal staff.
· Primary responsibilities will focus on product/dimensional engineering; however, the successful candidate must have casting process experience and be able to understand how changes in casting and investment shelling parameters effect metallurgical and dimensional integrity of Ni/Co based superalloy castings
· Work closely with other casting engineers to develop process engineering knowledge and take on joint process/product responsibilities as required by the business
· Develop core balance (wall control) and wax injection process to provide high yielding cast products
· Use wax reforming/setting and hot and cold metal forming techniques to optimize casting dimensions
· Review, analyze using SPC, and report out wall thickness (UT), dimensional inspection, and other product related yield data
· Work with, delegate tasks to, and mentor Jr Engineers and Engineering Technicians to expedite development trials and develop engineering talent within the business
· Update and maintain development schedules regarding NPI programs, assist program managers and sales managers with technical customer communication and trial status and results reports
· Attend and provide updates on customer calls regarding development trials, status and results
· Use 3D Modeling Software to review and modify customer supplied casting, core, and finished machined models to incorporate designs, stock, and other features to aid in the investment casting process.
· Design and model manufacturing support fixtures (Gate Grind, Cut off, Inspection), manage builds and qualification/validation of all part specific tools and dies
· Generate tooling letters and source fabrication of wax pattern dies and core tooling and fixture builds
· Establish First Article, probability studies, and production inspection plans
· Interpret and summarize inspection data. Translate inspection data into Layout Inspection Reports (i.e. AS9102 form) including summary of deviations report.
· Make technical cards/work instructions for production inspection operations
· Ability and willingness to work in other areas as needed.
· B.S. degree in mechanical engineering or similar discipline
· 3 to 5 years of casting, forging, or metal product manufacturing experience
· Fluent in the use of 3D modeling software (Unigraphics and/or Solidworks or similar)
· Fluent in MS Office suite of software specifically with MS Excel
· Statistical training, Six Sigma, /Use of Minitab also a plus
Job Type: Full-time
Salary: $85,000.00 to $95,000.00 /hour
- working with superalloy castings: 5 years (Required)
- Health insurance
- Dental insurance
- Vision insurance
- Retirement plan
- Paid time off
This Job Is Ideal for Someone Who Is:
- Dependable -- more reliable than spontaneous
- Adaptable/flexible -- enjoys doing work that requires frequent shifts in direction
- Achievement-oriented -- enjoys taking on challenges, even if they might fail