Utility Core Maker (Core Facility)

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