Foundry Metallurgist

Position

We are currently seeking a Foundry Metallurgist / Casting Engineer for our Steel and Iron Foundry in Decatur, Illinois.

Reporting directly to the Foundry Technical Manager, the Foundry Metallurgist / Casting Engineer is responsible to utilize process control and experience to insure the production of consistently high quality castings.

Safety:

• Review and approve foundry work instructions and PPE requirements to ensure safe operation.
• Ensure that outside vendors adhere to plant safety regulations and that MSDS for new and existing materials are reviewed, approved and filed.

Quality:

• Review foundry process control techniques to ensure measuring and recording techniques employed are accurate and that monitoring protocols are adequate to effectively control foundry processes and facilitate troubleshooting.
• Manage process control data within QCS and effect process changes to reduce scrap rates and improve product quality.
• Maintain an extensive knowledge of applicable quality standards and procedures. Establish/adhere, audit and enforce vendor quality procedures and specifications.
• Rig new manganese castings as well as improve rigging on current products. Provide input to the methods drawings in order to maintain legacy of successful rigging.
• Design and carry out test trials targeting product, process, and quality improvement.
• Maintain accurate records of materials, melt chemistry, and consumables for traceability and cost accuracy.
• Conduct root‑cause investigations of casting defects using metallurgical analysis and process‑troubleshooting methods.
• Train and assist foremen, supervisors, and operators in metal quality, sand control, and casting best practices.
• Monitor and adjust sand‑system parameters to maintain consistent mold quality while reviewing system trends and implementing corrective actions to eliminate variation.
• Review welding‑repair procedures for manganese castings, support welders with proper preheat, interpass‑temperature control, and filler‑metal selection, investigate weld‑repair defects, and implement process‑driven corrective actions to ensure all repairs meet metallurgical and customer specifications.
• Verify heat‑treatment furnace‑temperature uniformity, sensor calibration, and quench‑system parameters while conducting hardness testing and microstructural evaluations to confirm heat‑treat results.
• Troubleshoot heat‑treatment issues such as overheating, soft spots, and distortion, and implement the necessary process improvements.
• Troubleshoot and resolve issues with critical laboratory and process‑control equipment — including the spectrometer, sand‑lab testing instruments, and heat‑treatment system components — to ensure accurate and reliable operation.

On‑Time Delivery:

• Develop and implement plans to improve foundry productivity.
• Ensure timely development and verification of moulding and rigging.
• Manage relationships with internal/external customers and vendors to ensure appropriate communications to prevent delays due to sourcing or delivery issues.
• Collaborate with design and production teams to optimize manufacturing processes.

Cost:

• Establish metrics and data analysis to identify and trend cost concerns.
• Prepare cost estimates and schedules.
• Conduct failure analysis and develop and implement improvement plans.
• Ensures foundry processes minimize scrap and optimize yield.

People:

• Coach and mentor foundry technical and operating personnel.

Environmental:

• Adhere to Nortrak’s Environmental Procedures, Practices and Policies.

Other duties as assigned.

Education:

• Bachelor’s degree in Engineering, preferably in Material Science or Metallurgy.

Field of

Experience:

• At least five (5) years’ experience in steel foundry in an engineering or technical position.
• Experience with low volume/high component mix environment.
• Ability to troubleshoot foundry processes at the shop level.
• Experience with Data Analysis tools Mini‑tab or other Statistical software.
• Strong interpersonal, written, and oral communication skills are required.
• Must possess excellent negotiations, interpersonal and oral and written communication skills.
• Computer literate including Microsoft…