Foundry process operator jobs

It was difficult to work in a foundry 100 years ago. Noise, chemicals, poor lighting, high temperatures, and molten metal at temperatures approaching 3000° F were just a few of the hazards that came with foundry employment. Fast forward to 2018, and most of the risk in foundry labor has been lessened by mechanization, safety clothing and equipment, OSHA safety standards, and modern methods that serve to keep workers out of harm's way, as it does in most industrial industries.

In many circumstances, today's foundry worker is a jack-of-all-trades. Employees are cross-trained to prepare sand, pour metal, assemble cores, grind castings, and maybe work in the shipping department as needed, which is especially true in smaller enterprises.

However, in larger firms, each of these operations employs an individual or a department. A list of some of the tasks that make up a modern foundry may be found below. The final product and the distinct procedures they take to attain their individual processes determine the range of foundries.

Patternmaker

A pattern is the starting point for any casting. These are models made of wood, metal, or plastic that are used to make a sand mold. To make a casting, molten metal is poured into the sand mold. To construct patterns to the needed standards, patternmakers must be able to read and interpret blueprints as well as operate wood or metal shop equipment. Most patternmakers are obliged to complete a lengthy apprenticeship or vocational/technical training.

Engineer in Metallurgy

The metallurgical engineer is in charge of designing and revising pattern blueprints. While this is an engineering position, this person will be familiar with all aspects of the foundry, including heat treating concepts, metal testing protocols, quality control, certification documents, and the numerous mold operations.

The engineer may be involved in the casting quote and may be in charge of outsourcing any patterns that aren't created in-house. He or she would also be involved in the development of any new technologies or processes that the foundry implements. Engineers collaborate closely with customers to guarantee that castings meet all specifications and that any concerns with customer returns are resolved.

Coremaker

Sand cores are created separately from the mold and then inserted into it to create holes and hollow areas in the casting. The boxes are generally filled with sand on a core machine and serve the same purpose as patterns.

The coremaker's role is to clean the core box with compressed air before filling it and then remove the sand cores at the end of each cycle. Coremakers may be required to bake, assemble, or repair cores, depending on the procedure. They could also be involved in filling and packing the core box with sand.

Coresetter

Cores are mechanically put into molds in bigger automated foundries, although many foundries still do it manually. The coresetter is in charge of ensuring that the core is appropriately positioned in the open mold. Coresetters also inspect the mold and cores for faults, use gages to evaluate the distance between the mold and the core, and help close the mold. At times, they may be required to use a hoist or jib crane.

Pouring Metal

Metal pourers gather samples, read temperature gauges, and adjust furnace flames or electrical heating units so that the metal melts to specifications in addition to pouring and regulating the flow of molten metal into molds. They've also been taught to look for flaws and color changes in the metal.

Some pourers inspect molds for smoothness and cleanliness. They may also be charged for eliminating surplus metal from ingots and equipment and collecting scrap for recycling.

Grinder for Casting

Because castings are made with two mold halves, any minor gap between them may cause unwanted metal to leak out at the junction. These flaws, known as flashing or fins, are ground out in a secondary operation.

Casting grinders must be meticulous and capable of lifting and handling some quite hefty castings. Grinding wheels are rotating at high RPMs, thus any lapses in focus could be harmful.

Every Foundry Has a Solution

Do you have a question about how GK equipment may help your foundry? Speak with one of our expert employees. Our professional staff can create custom solutions for your foundry material handling requirements. Rest confident that no matter where you are, we will assist you in getting started with high-quality equipment that will meet and surpass your expectations.