Foundry Metallurgist/Casting Engineer

VOESTALPINE RAILWAY SYSTEMS NORTRAK LLC; Decatur (IL); On-site; USD 75,000 - 90,000; Full time

Job summary

voestalpine Railway Systems Nortrak is seeking a Foundry Metallurgist/Casting Engineer in Decatur, IL to ensure high-quality castings through process control and metallurgical expertise. The role requires a bachelor's degree in metallurgy or materials engineering and 5+ years in a steel foundry environment.

You will lead process improvements, troubleshoot casting and heat-treatment issues, and mentor shop staff while maintaining safety, quality, and on-time delivery. Competitive salary offered.

Qualifications

• Bachelor’s degree in Engineering with focus on metallurgy or materials science.
• 5+ years of experience in steel foundry engineering or technical roles.
• Ability to troubleshoot foundry processes at shop level and analyze metallurgical data.
• Proficiency with SAP and data analysis tools.

Responsibilities

• Ensure safe operation by reviewing work instructions and PPE requirements.
• Improve product quality by controlling process data and reducing scrap.
• Develop and test improvements in product, process and quality.
• Coach and mentor foundry personnel and ensure adherence to procedures.
• Collaborate with design/production teams to optimize manufacturing processes.
• Ensure environmental, safety, and cost targets are met.

Skills

Metallurgical testing

Process control

Data analysis

Interpersonal communication

Microsoft Excel

Education

Bachelor’s degree in Engineering (Material Science/Metallurgy)

Tools

SAP

MiniTab

Statistical software

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Foundry Metallurgist/Casting Engineer

Full Time Salaried Exemp Decatur, IL, US

2 days ago Requisition ID: 2334

Salary Range: $75,000.00 To $90,000.00 Annually

Join Our Team at voestalpine Railway Systems Nortrak!

Embark on a rewarding career journey with voestalpine Railway Systems Nortrak, North America's premier designer and manufacturer of special trackwork. With a legacy spanning 160 years, we lead the industry in shaping the future of rail solutions. As part of the voestalpine Railway Systems global network, we are committed to delivering quality products and services, including rails, turnouts, fastening systems, signaling technologies, and monitoring solutions. Operating with a presence across Canada, the US, and Mexico, we prioritize the well-being of our people, global mobility, and sustainability and innovation.

Our people are the foundation of our success. Skilled, motivated, and results-driven individuals shape our culture demonstrating our core values of Respect, Responsibility, Curiosity, Courage, Passion, and Diversity each day. This commitment is more than shared values; it extends to shared responsibilities for safety and quality, showing genuine care for one another's growth and development, a commitment to our customers, and fostering strong relationships within the Nortrak Team and with our customers.

We are currently seeking a Foundry Metallurgist /Casting Engineer for our Steel and Iron Foundry in Decatur, Illinois.

PURPOSE OF POSITION

Reporting directly to the Foundry Technical Manager, the Foundry Metallurgist /Casting Engineer is responsible to utilize process control and experience to insure the production of consistently high quality castings.

TASKS & RESPONSIBILITIES

SAFETY

• Review and approve foundry work instructions and PPE requirements to ensure safe operation.
• Ensure that outside vendors adhere to plant safety regulations and that MSDS for new and existing materials are reviewed, approved and filed.

QUALITY

• Review foundry process control techniques to ensure measuring and recording techniques employed are accurate and that monitoring protocols are adequate to effectively control foundry processes and facilitate troubleshooting.
• Manage process control data within QCS and effect process changes to reduce scrap rates and improve product quality.
• Maintain an extensive knowledge of applicable quality standards and procedures. Establish/adhere, audit and enforce vendor quality procedures and specifications.
• Rig new manganese castings as well as improve rigging on current products. Provide input to the methods drawings in order to maintain legacy of successful rigging.
• Design and carry out test trials targeting product, process, and quality improvement.
• Maintain accurate records of materials, melt chemistry, and consumables for traceability and cost accuracy.
• Conduct root ‑ cause investigations of casting defects using metallurgical analysis and process ‑ troubleshooting methods.
• Train and assist foremen, supervisors, and operators in metal quality, sand control, and casting best practices.
• Monitor and adjust sand ‑ system parameters to maintain consistent mold quality while reviewing system trends and implementing corrective actions to eliminate variation.
• Review welding ‑ repair procedures for manganese castings, support welders with proper preheat, interpass ‑ temperature control, and filler ‑ metal selection, investigate weld ‑ repair defects, and implement process ‑ driven corrective actions to ensure all repairs meet metallurgical and customer specifications.
• Verify heat ‑ treatment furnace ‑ temperature uniformity, sensor calibration, and quench ‑ system parameters while conducting hardness testing and microstructural evaluations to confirm heat ‑ treat results.
• Troubleshoot heat ‑ treatment issues such as overheating, soft spots, and distortion, and implement the necessary process improvements.
• Troubleshoot and resolve issues with critical laboratory and process ‑ control equipment — including the spectrometer, sand ‑ lab testing instruments, and heat ‑ treatment system components — to ensure accurate and reliable operation.

ON-TIME DELIVERY

• Develop and implement plans to improve foundry productivity.
• Ensure timely development and verification of moulding and rigging.
• Manage relationships with internal/external customers and vendors to ensure appropriate communications to prevent delays due to sourcing or delivery issues.
• Collaborate with design and production teams to optimize manufacturing processes.

COST

• Establish metrics and data analysis to identify and trend cost concerns.
• Prepare cost estimates and schedules.
• Conduct failure analysis and develop and implement improvement plans.
• Ensures foundry processes minimize scrap and optimize yield.

PEOPLE

• Coach and mentor foundry technical and operating personnel.

ENVIRONMENTAL

• Adhere to Nortrak's Environmental Procedures, Practices and Policies.

Other duties as assigned.

QUALITIFCATIONS

EDUCATION

• Bachelor’s degree in Engineering, preferably in Material Science or Metallurgy.

FIELD OF EXPERIENCE

• At least five (5) years’ experience in steel foundry in an engineering or technical position.
• Experience with low volume/high component mix environment.
• Ability to troubleshoot foundry processes at the shop level.
• Experience with Data Analysis tools Mini-tab or other Statistical software.
• Strong interpersonal, written, and oral communication skills are required.
• Must possess excellent negotiations, interpersonal and oral and written communication skills.
• Computer literate including Microsoft Excel Spreadsheets. SAP knowledge and/or experience would be an asset.
• Proficiency in metallurgical testing and analysis methods.
• Understanding of thermodynamics, phase diagrams, and material properties.
• Attention to detail and high standards of quality.
• Familiarity with metallurgical software and analysis tools.

PHYSCIAL DEMANDS

• Prolonged periods of sitting at a desk and working on a computer; occasional standing and walking for your scheduled shift.
• Must remain stationary for extended periods and move throughout the building to access files.
• Must work effectively in a noisy environment.
• Ability to lift and move equipment or objects up to 20-25 pounds occasionally.
• Visual requirements include close, distance, color, peripheral vision, depth perception, and the ability to adjust focus.
• Occasional travel required, involving walking, standing, sitting, and driving for varying durations.
• Site inspections required to identify and address safety concerns.
• Frequent use of hands and arms for dialling phones and using a computer mouse.

WORKING LOCATION

• $75,000/year - $90,000/year
• A supportive, family oriented Nortrak Blue culture.
• We provide an environment where Health and Safety is our #1 priority.
• Career development opportunities and competitive pay progression.
• Company paid life and disability insurance.
• Paid holidays and vacation.
• Retirement plan with matching contributions.
• Tuition Assistance Program.
• Wellness Program.
• Employee Assistance Program.
• Employee Recognition Programs.

voestalpine Railway Systems Nortrak (“Nortrak”) is a subsidiary of voestalpine AG ( www.voestalpine.com ) one of Europe’s premier steel producers with over 50,000 employees worldwide. Nortrak is closely affiliated with voestalpine’s Railway Systems group which operates in 21 countries across the globe to provide cutting edge system-based solutions to railroads and transits. Our website is https://www.voestalpine.com/nortrak/en/

voestalpine Railway Systems Nortrak is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected Veteran status, and any other federal, state, or locally protected classifications.