Utility Core Maker (Core Facility)

About the Role

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

Responsibilities

• Slurry Makeup and Testing: Make slurries within established process specifications. Check pH, viscosity, temperature, and gel times; apply results to specification ranges to determine slurry usability. Modify slurries to bring into specification without altering core requirements. Record time and track work in progress.
• Invested Core Processing: Fabricate acceptable ceramic cores using the Invested Core Process.
  • Inspect soluble for defects and decide on usability.
  • Assemble soluble patterns, which differ for each core configuration; help develop new assembly techniques.
  • Build wax shell of assembled pattern.
  • Leach soluble from wax shell.
  • Build alpha-coated core, attending to surface quality, stucco, and adhesion before applying the next layer.
  • Fill remaining cavity with core pack.
  • De-wax in hot wax tank and fire in furnace.
  • Record time and track work in progress.
• High Pressure Injection: Produce ceramic cores by high pressure injection molding.
  • Operate high pressure machines per established process; monitor temperature and pressure.
  • Monitor inventory levels of high-pressure ceramic mix and order materials as needed.
  • Assist in the preparation of high-pressure ceramic mix.
  • Place green state cores in sand-filled trays and transport trays.
• Low Pressure Injection: Produce ceramic cores by low pressure slurry injection molding.
  • Operate low pressure machines per established process specifications to produce cores of acceptable quality.
  • Remove binder using flaming, ovens, or water as needed.
  • Record time, track work in progress, and mark core I.D.
• Plasma Spraying: Deposit a controlled thickness of non-reactive coating material on cores using plasma spraying.
  • Set up and operate plasma spray unit.
  • Apply uniform thickness by measuring cores before, during, and after plasma spraying.
• Setter Production: Fabricate setters used as firing fixtures that directly influence the dimensional acceptability of ceramic cores.
  • Fabricate and reface setters by pouring slurry into mold cavity, removing binder, and firing setters.
• Core Repair: Repair ceramic cores after firing using established techniques.
  • Inspect cores for surface defects, flash, positives and negatives, and air pockets.
  • Repair identified defects using established techniques.
• Firing: Fire ceramic cores in furnace to increase strength and gain dimensional stability.
  • Load and unload setters and product per specifications.
  • Set up and operate furnace per instructions.
• Safety: Take responsibility for and demonstrate safe work practices.
  • Adhere to plant and department safety rules.
  • Safely operate all equipment and tools.
  • Identify and report safety problems.
  • Wear all personal protective equipment as necessary.
  • May be required to work with hazardous waste.
• Other Duties:
  • Perform minor maintenance on equipment as needed.
  • Package and ship product.
  • Perform material testing as required.
  • Complete all logs and records.
  • Meet all production and quality standards.
  • Perform other tasks as directed.

Equipment Used

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