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  • Job reference: RMS0098428

Technical Specialist – Metal Castings

  • Sector: Automotive
  • Location: Coventry
  • Job type: Permanent
  • Date posted: 04/10/2011
We're sorry this position has now been filled.

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The Company:
Is a leading Automotive manufacturer and is currently experiencing an upturn in production with demand increasing globally.

The Role:
Key responsibilities :-

Knowledge of metal casting related activities including;-

Foundry plant operations relating to high and low pressure die, sand and permanent mold Aluminium casting processes used for the production of automotive engine components.
Metal casting foundry techniques commonly employed for quality control, robust design processes and
Experience of analytical tools producing optimised designs for quality assured casting integrity, performance, manufacturability and cost.
Metal furnace, melt preparation, refinement and treatment, raw material sourcing and specification/quality control. Melt composition analysis – to achieve required precise chemistry and microstructure.
Casting integrity, analysis of defects, cost estimating,
Sand, HPDC/LPDC and permanent mold, sand core production
Dimensional tolerance capability, surface finish
Creation of engineering specifications and part prints
Pattern tool design, gating system design, use of in-mold analytical flow modelling tools, solidification analysis tools, sand core blowing
Demonstrate knowledge/experience in the development of casting designs for strengthening, weight reduction, cost and quality assurance/improvement
Metal preparation and pouring
Finishing processes (flash removal, cleaning, repair processes e.g. welding and impregnation)
Material selection [Aluminium alloy, cast irons, steels]
Prototype casting
Rapid prototype
Supplier technical assistance support, resolution of quality issues, quality assurance
Foundry quality control and inspection processes (NDA and destructive) processes
Creation and maintenance of requirements/design rules/robust design and analysis processes to ensure the quality of castings. Mistake prevention. Design for Manufacture.
Support in-house engine component machining teams
Provide training and the creation of training material
Support supplier production and prototype value for money on tooling
Support the design of lightweight, cost efficient high quality castings for automotive IC engines
Knowledge of heat treatment processes for mechanical property optimisation
Support the development of an as-cast material mechanical property database to support CAE
Failure analysis PFMEA/DFMEA
Assess, update, and maintain technical resources such as specification manuals, papers, and reference information
Stay abreast of industry developments in order to support and advise on technical and research projects.
Lead/support activities of associated research activities including the development of grant application project proposals and project management.
Publications and patents
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