Utility Core Maker

PRINCIPAL ACCOUNTABILITY:

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.

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.

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.

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

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.

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.

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

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

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.

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.

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.

• 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.

• Basic hand tools (e.g. wrenches, sockets, hammers, etc.)
• Dimensional measuring tools (e.g. calipers, micrometers, gauges)
• high shear mixer
• thermometer, pH meter and viscosity cup
• slurry pots
• planetary mixer
• leach tank
• knives and files
• hot wax tanks
• pallet jacks
• hand grinders
• hand drills
• masonry band saws

• 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.

• 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…