Foundry Process Engineer - Gray & Ductile Iron Castings

Weatherly Casting and Machine Co; Weatherly (Carbon County); On-site; USD 90,000 - 120,000; Full time

Job summary

Weatherly Casting and Machine Co is seeking an experienced Foundry Engineer to optimize gray and ductile iron casting processes on the production floor. You will develop tooling, gating and riser systems, and control documentation to improve quality and yield.

You will analyze process data, lead continuous improvement projects, and collaborate with quality, production and engineering teams to meet customer specifications and safety requirements.

Qualifications

• Hands-on foundry experience with gray iron and ductile iron.
• Bachelor’s degree in Engineering or related field or equivalent experience.
• 3–5 years of relevant foundry/manufacturing experience.
• Strong knowledge of metal casting, molding, gating and risering, tooling, and process control.
• ASNT Level II nondestructive testing certification for MPT and DPT.
• Experience with ISO quality systems, methods, procedures, and audits.
• Understanding of metallurgy, materials, and quality-control principles.
• Ability to analyze data, identify root causes, and develop corrective actions.
• Strong written and verbal communication across engineering, quality, and production.

Responsibilities

• Promote safety culture and ensure compliance with safety and environmental requirements.
• Develop and optimize foundry processes for gray and ductile iron castings.
• Design gating, riser systems and tooling using 3D modeling and casting simulation.
• Create and maintain process control documentation for molding, core making, and 3D sand printing.
• Analyze foundry data to identify root causes and drive continuous improvement.
• Participate in evaluation and implementation of new manufacturing technologies (3D scanning, 7-axis mold milling, 3D sand printing, automated grinding).
• Inspect and test products with metrology equipment, MPT, DPT, hardness and mechanical tests.
• Prepare technical reports and SOPs; lead internal ISO audits with cross-functional teams.

Skills

Foundry operations

Gray iron casting

Ductile iron casting

Process control

Quality systems

Root cause analysis

3D modeling

Casting simulation

Tooling design

Data analysis

Communication

Education

Bachelor's degree in Engineering

Equivalent combination of education and experience

Tools

Odyssey ERP

Casting simulation software

3D modeling software

Job description

Weatherly Casting and Machine Co is seeking an experienced Foundry Engineer to optimize gray and ductile iron casting processes on the production floor. You will develop tooling, gating and riser systems, and control documentation to improve quality and yield.

You will analyze process data, lead continuous improvement projects, and collaborate with quality, production and engineering teams to meet customer specifications and safety requirements.