Utility Core Maker (Core Facility

Position: Utility Core Maker (Core Facility)
Job Description

MISSION:

To fabricate ceramic cores via low pressure injection, high pressure injection, and invested core processes; to work independently to assure smooth product flow through all aspects of core production.

PRINCIPAL ACCOUNTABILITY:

Slurry Makeup and Testing: to make slurries within established process specifications.

* Essential Job Functions:

* Many different slurries are used; checks pH, viscosity, temperature, and gel times, applies results to specification ranges and determines whether slurries are usable.

* If needed, modifies slurries to bring into specification without altering slurry with respect to core requirements.

* Records time, tracks work in progress.

Invested Core Processing: to fabricate acceptable ceramic cores by the Invested Core Process.

* Essential Job Functions

* Inspects soluble for defects; decides on usability.

* Assembles soluble patterns which differ for each core configuration; helps develop new assemble techniques.

* Builds wax shell of assembled pattern.

* Leaches soluble from wax shell.

* Builds alpha coated core, attending to surface quality, stucco and adhesion before next layer is applied.

* Fills remaining cavity with core pack.

* De-waxes in hot wax tank and fires in furnace.

* Records time, tracks work in progress.

High Pressure Injection: to produce ceramic cores by high pressure injection molding.

* Essential Job Functions:

* Operates high pressure machines per established process; monitors temperature and pressure.

* Monitors inventory levels of high pressure ceramic mix and orders materials as needed.

* Assists in the preparation of high-pressure ceramic mix.

* Places green state cores in sand-filled trays, transports trays

Low Pressure Injection: to produce ceramic cores by low pressure slurry injection molding.

* Essential Job Functions:

* Operates low pressure machines per established process specifications to produce cores of acceptable quality.

* Removes binder by using either flaming, ovens or place under water as needed.

* Records time; tracks work in progress; marks core I.D.

Plasma Spraying: to deposit a controlled thickness of a non-reactive coating material on the cores using plasma spraying.

* Essential Job Functions:

* Sets up and operates plasma spray unit.

* Applies uniform thickness by measuring cores before, during and after plasma spraying.

Setter Production: to fabricate setters used as a firing fixture which directly influence the dimensional acceptability of ceramic cores.

* Essential Job Function:

* Fabricates and reface setters by pouring slurry into mold cavity; removes binder; fires setters.

Core Repair: to repair ceramic cores after firing using established techniques.

* Essential Job Functions:

* Inspects cores for surface defects, flash, positives and negatives, and air pockets.

* Repairs identified defects using established techniques.

Firing: to fire ceramic cores in furnace to increase strength and gain dimensional stability.

* Essential Job Functions:

* Loads and unloads setters and product per PCC specifications.

* Sets up and operates furnace per instructions.

Safety: to take responsibility for and demonstrate safe work practices.

* Essential Job Functions:

* Adheres to plant and department safety rules.

* Safely operates all equipment and tools.

* Identifies and reports safety problems.

* Wears all personal protective equipment as necessary.

* May be required to work with hazardous waste.

OTHER DUTIES

* Performs minor maintenance on equipment as needed.

* Packages and ships product.

* Performs material testing as required.

* Completes all logs and records.

* Meets all production and quality standards.

* Performs other tasks as directed.

ESSENTIAL EQUIPMENT, VEHICLES, TOOLS AND/OR MACHINERY USED:

* Basic hand tools (e.g. wrenches, sockets, hammers, etc.)

* Dimensional measuring tools (e.g. calipers, micrometers, gauges)

* furnace

* Injection Molding presses

* high shear mixer

* thermometer, pH meter and viscosity cup

* forklift

* plasma spray unit

* slurry pots

* planetary mixer

* dryer ovens

* vacuum chambers

* leach tank

* knives and files

* hot wax tanks

* scales

* hoists

* pallet jacks

* hand grinders

* hand drills

* masonry band saws

* hot pencils

TRAINING

* On the job training is provided.

* PCC's Forklift Driving Safety Certification Training must be completed.

* May be required to complete hazardous waste management training.

QUALIFICATIONS

* Experience with ceramics or investing preferred.

* Ability to read and interpret Process Control Procedures, Technique Cards and other technical specifications.

* Ability to work independently with minimal supervision.

* Ability to assess out-of-norm situations, institute corrective actions, and maintain production flow.

* Ability to perform basic mathematical calculations. (addition, subtraction, multiplication, division)

* Ability to communicate effectively, both verbally and in writing.

* Physical ability to lift and push

This position requires use of information or access to production processes subject to national security controls under U.S. export…