CASTER/MOLD HANDLER

Howmet Aerospace’s Wichita Falls, TX facility is a world leader in the investment casting industry and a leading supplier of superalloys, aluminum, and titanium components for aerospace, automotive, and commercial transportation applications.

About the role

Responsible for operation of casting unit; melts and pours into ceramic molds using induction or vacuum induction furnaces according to critical, prescribed written instructions and procedures. Works under general supervision and the direction of a caster to remove molds from the preheat furnace, properly position in a timely manner for casting, perform wrap application, dewaxing, repair, mold inspect and perform all post-cast operations specified. Works with a mold-handler and at times performs the mold-handling operation to preheat ceramic molds and melt alloy to pour into the preheated molds.

Responsibilities

Caster

• Inserts alloy charges into an induction melting crucible (air or vacuum) manually or with mechanical assistance.
• Operates casting unit to melt charge, either manually or utilizing autocast system; monitors melt visually and ascertains temperatures with pyrometer or immersion thermocouple.
• Directs mold handler to convey mold from preheat furnace to casting unit.
• Monitors and records casting parameters required in casting log and computer.
• Confirms correct alloy identification and casting sequence of molds.
• Warns mold handler of broken or leaking molds.
• Supplies mold handler with alloy identification tags and notifies mold handler of any “capping” material required on molds.
• Manually pours or adjusts and initiates auto pour of melted charges.
• Removes and installs induction crucibles.
• Cleans casting unit along with the inner walls of the melt chamber.
• Keeps updated on all Activity Instructions.
• Assists in minor equipment maintenance.
• Expected to lead a team of foundry service operators and mold handlers to perform to a given schedule supplied by the Supervisor.
• Complies with all EHS rules related to the work environment.
• Works overtime when needed.

Mold Handler

• Reads all available instructions and assists caster to cast molds in accordance with established techniques and specific instructions on the Product Criteria, Mold Sheets, or Activity Instructions.
• Assists in the acquisition of the proper alloy, checks preheat temperatures, handles the molds from the preheat furnace and again after casting, and accomplishes all specific post-cast operations (Hexamine, mold stripping, exothermic application, and vermiculite encapsulation).
• Ensures proper mold positioning, lower chamber cleaning, and the control of variables affecting solidification and mold cooling.
• Moves empty, hot furnace trays, changes and cleans door gaskets, performs heavy housekeeping required in department, and assists in minor equipment maintenance.
• Notifies caster of any torn wraps, bumped, or leaking molds.
• Periodically loads ovens.
• Locates scheduled work, moves trucks to proper workstation.
• Ensures molds are kept clean in each area.
• Seals molds at dewax or mold inspection with either ceramic disk or rubber cap.
• Monitors operation of equipment and temperature controls.
• Inspects and repairs molds.
• Prepares solutions and maintains supplies.
• Cuts required kaowool and rollboard.
• Wraps molds per Process Releases/Product Criteria.
• Operates the required piece of mobile equipment for this area.
• Keeps machines and work area clean and in orderly condition.
• Notifies supervisor immediately of equipment or machinery malfunctions.
• Completes necessary paperwork as required.
• Verifies mold counts and paperwork correctness on lot travelers or serial numbers at each operation.
• Loads molds in preheat oven.
• Performs other duties as required.
• Complies with all EHS rules related to the work environment.
• Works overtime when needed.

Requirements

• Must be able to read and interpret Product Criteria (PC) and Activity Instructions (AI).
• Must be able to function as a member of a team and work under general supervision.
• Must be able to maintain expected quality levels.
• Comply with all site required policies and procedures including but not limited to: EHS, Quality, Code of Conduct, and the Wichita Falls Employee Handbook.
• Using computers (entering information, etc.).
• Independent judgment is often required when performing job duties.
• Considerable care and attention are required while operating the casting unit.

Physical Demands

• Considerable physical effort is required when loading alloy.
• Reach for items nearby, far, and overhead.
• Fine manipulation, using a keyboard and mouse.
• Lifting and carrying to the waist-to-chest high level, floor to waist, and chest to overhead.
• Gripping, pinching, and handling.
• Climb stairs and ladders.
• Crawl, squat, balance, and sustain bending.
• Finger press and tolerate hand/arm vibration.
• Carry with one hand.
• Pushing, pulling, and twisting.
• Carry items with two hands.
• Moderate lifting from 25 lbs to 50 lbs.
• Almost constant standing and sufficient strength to lift, handle, and transport heavy, hot molds, and hot molds containing molten alloy.
• Must pass Jaeger 2 vision test annually for depth perception when pouring alloy and setting mold position.

Work Environment

• Extreme care must be taken because of exposure to extremely high temperatures for short periods of time.
• Exposure to dust and fumes from the casting process.
• Occasional exposure to uncontained molten metal sprays and solid metal chips from chamber cleaning.
• Requires wearing a dust mask during certain procedures.
• Exposure to Nickel and RCF.

Equipment Used

• Miscellaneous hand tools, pyrometer, and immersion thermocouple.
• Roll-over and vacuum furnaces.
• Assorted digital read-out and dial type displays.
• Hoist and other handling tools to manipulate molds into the casting furnaces, cooling stations, and onto cooling carts.

Training

Three to six months on-the-job training required for satisfactory job proficiency, covering:

• Training Folder
• Molten Material
• Combustion Systems
• Hazardous energy sources (LTV)

Qualifications

Basic Qualifications

• High School Diploma or GED from an accredited institution.
• Must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire. Visa sponsorship is not available for this position.
• This position entails access to export-controlled items and employment offers are conditioned upon an applicant's ability to lawfully obtain access to such items.

Preferred Qualifications

• Basic computer skills.
• Foundry Service/Mold Handler experience.

Schedule

MUST BE ABLE TO WORK 12 HOUR ROTATING SHIFTS: (2 on 2 off, 3 on 2 off, 2 on 3 off). Positions are available on each shift.

Pay

Starting pay is $29.31, topping out at $33.88 at 9 months. $1.00 shift differential included.

Benefits

• Paid vacation each year, based on length of service.
• Paid holidays.
• 401(k) Retirement Savings Plan with company match of up to 6% of pre-tax contributions.
• Employer contribution to Retirement Savings Plan account each pay period.
• Medical, prescription drug, dental, and vision benefits offered upon hire.
• Employee Life Insurance.
• Employee Assistance Program.