Die Casting Process Engineer

General Motors; Bedford (IN); On-site; USD 90,000 - 120,000; Full time

Job summary

General Motors is seeking a Die Casting Process Engineer to support development and launch of high pressure die casting programs. You will work with product and equipment engineers on tooling design, evaluate simulation results, and perform process setup on the plant floor.

The role requires hands-on experience with casting shop activities, strong knowledge of PFMEA and process control plans, and collaboration with cross-functional teams to ensure successful program launches.

Qualifications

• Foundry experience and ability to apply casting concepts in manufacturing.
• Knowledge of high pressure die casting or related tooling/quality
• Understanding of aluminum chemistry, heat treatment, metallurgical processes

Responsibilities

• Support launch validations, build plans, PPAP and related procedures.
• Assist testing and installation of equipment, tooling, and technologies on and off site.
• Lead analysis of casting defects and present findings to cross-functional teams.
• Develop process documentation including PFMEA, PCP, and process control plans.
• Analyze first time quality data and optimize processes using DOE and statistical tools.
• Perform non-destructive testing and process start up on the plant floor.

Skills

Die casting knowledge

Manufacturing concepts

DOE and statistics

Mechanical concepts

Education

BS in Engineering or Metallurgy

Tools

Magma

Flow 3D

Job description

The Die Casting Process Engineering Team excels in the development, testing, implementation and execution of new die casting programs, platforms and technology. This group with our product engineering, equipment engineers, and plant teams to develop and launch high pressure die castings supporting General Motors entire portfolio, including engine, transmission, drive unit, and structural castings.

By working with a cross functional team of die casting engineers, you will execute casting manufacturing projects by following a systematic engineering process of evaluation, development, validation, and technology transfer leading into and supporting the launch of new die casting products. You will be responsible for working with product engineers and die OEMs on the process and tooling design, reviewing and interpreting simulation results, and process setup and startup on the plant floor.

Key job functions:

• Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering procedures
• Support testing and installations of equipment, tooling and technologies both on and off site
• Lead, support and present the analysis of casting defects
• Assist in process, tooling and equipment testing, troubleshooting and implementations
• Develop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launch
• Analyze first time quality data and optimize processes using DOE, Red X, and related statistical tools
• Perform both Non and destructive testing procedures for casting investigation and analysis ( leak testing, x ray, CT, thermal, lab specimen prep, chemistry, density, mechanical, etc)
• On site work, working on shop floor, hands on equipment, understanding of casting shop activity,( climbing, bending, lifting, in and around Hot aluminum)

Basic Qualifications

• Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
• High Pressure Die Casting, or similar tooling, process, quality, or project management experience
• Functional knowledge of aluminum chemistry, heat treat, metallurgical processes
• Knowledge of process engineering procedures and disciplines such as PFMEA’s and Process Control Plans
• Demonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary casting post

Preferred Experience:

• Training in aluminum metallurgy
• Prior manufacturing experience in high pressure die casting
• Training in flow simulations (Magma, Flow 3d)

Education:

• BS degree (Engineering, Metallurgy) or equivalent experience is required