Metallurgist

About the role You’ll own the metallurgy of our melt and cast operations. From charge makeup and inoculation through lab testing and PPAPs, you’ll keep gray/ductile iron within spec, reduce scrap, and coach the floor on best practices. What you’ll do Melt & chemistry control Set and maintain charge calculations (returns, scrap, pig, alloys) for cupola/induction. Control C, Si, Mn, S, P and carbon equivalent; manage de‑S, inoculation, and Mg treatment to achieve nodularity and chill targets. Define process windows for superheat, holding time, ladle/slag practices, and treatment recovery. Metallurgy lab & compliance Run/oversee OES spectrometer, C/S analyzer, thermal analysis, hardness (HBW), tensile (ASTM A370/E8), and metallography per ASTM A247. Maintain calibrations, procedures, and LIMS/records; ensure material traceability and test coupon compliance. Author and maintain melt practice SOPs and control plans; support ISO 9001 / IATF 16949 and customer audits. Quality & problem solving Lead root‑cause (8D), PFMEA, and SPC for metallurgical scrap (carbides, shrink, porosity, graphite morphology, pearlite/ferrite balance). Drive corrective/preventive actions with Foundry/Pattern/Sand teams; verify effectiveness with data. Partner with Maintenance on furnace/ladle reliability and with Sand on metal–mold interactions. New products & customer support Review specs (ASTM A48/A536 and customer‑specific), set acceptance criteria, and complete PPAPs (capability, control plans, MSA). Provide metallurgical feasibility for gating/feeding and heat treatment where applicable; support NDT requirements. Training & leadership Train melt operators, pourers, and lab techs on sampling, treatment windows, and visual standards. Publish daily melt reports and lead cross‑shift metallurgical review. What you’ll bring B.S. in Metallurgical/Materials Engineering (Mechanical/Chemical with strong foundry experience considered). 3–5+ years in an iron foundry (gray and/or ductile) with hands‑on melt control and lab leadership. Green‑sand/core knowledge Deep knowledge of inoculation/Mg treatment, thermal analysis, chill control, and microstructure targets. Comfortable with SPC/Minitab or similar, PPAP/IATF 16949, and customer specs. Strong communicator who thrives on the floor and in the lab; able to influence across shifts. Nice to have MAGMA/SOLIDCast (or similar) exposure NDT familiarity Six Sigma Green Belt Automotive experience KPIs you’ll own First‑time‑right chemistry hit rate Metallurgical scrap rate and cost/ton Lab turnaround time & calibration adherence PPAP on‑time/first‑pass yield Melt yield and alloy consumption variance