Precision Castparts
Master Caster Furnace Operator LPCS 035
Precision Castparts, Portland, Oregon, United States, 97204
Mission
To efficiently and safely operate the Master Caster and Air Master Melt Furnaces to consistently produce alloys to meet PCC's metallurgical specifications. To produce vacuum ingots and castings.
Principal Accountabilities
Preparation: Objective – To check equipment and assure accurate proportions of each element in alloys produced in compliance with all Process Control Procedures.
Essential Job Functions
Checks vacuum level, power supplies, liners and other furnace systems.
Prepares metal materials for air master melt and master caster process to meet element proportions per metallurgist schedule.
Builds Master Heat recipes using an alloy blending system.
Weighs materials to be melted (Revert and Virgin).
Uses and updates Electronic Heat Log and Furnace Clocks.
Loads and fires shells in burnouts in accordance with requirements, monitoring all shell temperatures throughout the cycle.
Prepares all charges and recharges for furnace loading, including welding of hooks for overhead lifting.
Notifies appropriate personnel of low raw material levels as needed.
Orders raw materials (Revert, alloy and elements) as needed for production.
Maintains and monitors vacuum levels throughout melts according to PCC specifications.
Charges furnace by adding virgin or revert materials as required.
Takes sample of molten metal for lab analysis; makes calculations and adjusts the composition when out of range (using an alloy blending system).
Approves start of pouring process when heat composition meets specifications.
Enter pour programs for each work order to be poured on Master Heat.
Operates the Master Caster furnace to pour alloy ingots and large vacuum castings; operates hydraulic systems, doors, cranes and hoists.
Assembles air casting bottom pour ladles and trigger mechanisms.
Operates Air Master Melt furnace to pour alloy ingots and large castings; operates hydraulic systems, large overhead cranes and bottom pour ladles.
Slag, de‑ox and prepares air master melt heats in a variety of alloys for pouring into ingots and castings.
Pours test bar material to the casting specifications for each heat.
Rebuilds Master Caster bottom pour ladle systems, including backpacks, stopper rods, nozzles and hosts.
Weighs, marks and documents all heats correctly throughout the master melt process.
Maintains and monitors condition of melting coils, furnace linings, pouring ladles and equipment.
Cleans furnace of soot deposits.
Rebuilds vacuum ladles and backpack actuators.
Leak checks and repairs minor or major vacuum leaks.
Changes oil in diffusion and other pumps.
Troubleshoots mechanical and electrical failures on furnace systems.
Rebuilds burnout furnaces as needed.
Works with maintenance to perform preventative maintenance and repair the furnaces as needed.
Completes accurate logs, production reports and records.
Provides work direction, training, and working supervision as assigned.
Meets all production and quality standards.
Adheres to plant and department safety rules.
Safely operates all equipment and tools.
Identifies and reports safety problems.
Equipment, Vehicles, Tools And/Or Machinery Used
Air Master Melt Furnace
Master Caster Furnace
Burnout furnaces (for Air Casting and Vacuum Casting)
Pneumatic tools (e.g., air hammers, air chisels)
Forklift
Hoists
Overhead crane
Special lifting devices
Hydraulic presses
Electric rammer
Basic hand tools (e.g., wrenches, screwdrivers, prybars, etc.)
Torches (gas, air arc, arc welding)
Electric grinder
Linear actuators
Drill press
CB radios
Training
Training is provided on the job.
PCC's Forklift Driving Safety Certification Training must be completed.
Qualifications
Basic knowledge of vacuum and air master melt operations and vacuum furnace operations as demonstrated by competent performance of all Assistant Master Melt Vacuum Furnace Operator duties, or equivalent combination of experience and training.
Ability to read, interpret, and follow specifications on Technique Cards, Process Control Procedures and Standard Operating Procedures.
Ability to perform basic mathematical calculations (addition, subtraction, multiplication, division) and calculate percentages.
Ability to work independently and as a team member, with limited supervision.
Ability to provide work direction and coordinate the work of others.
Ability to communicate effectively, both verbally and in writing.
Physical ability to perform essential job functions.
Ability to use computer interfaces to enter master melt and casting data and build heat requirements.
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Principal Accountabilities
Preparation: Objective – To check equipment and assure accurate proportions of each element in alloys produced in compliance with all Process Control Procedures.
Essential Job Functions
Checks vacuum level, power supplies, liners and other furnace systems.
Prepares metal materials for air master melt and master caster process to meet element proportions per metallurgist schedule.
Builds Master Heat recipes using an alloy blending system.
Weighs materials to be melted (Revert and Virgin).
Uses and updates Electronic Heat Log and Furnace Clocks.
Loads and fires shells in burnouts in accordance with requirements, monitoring all shell temperatures throughout the cycle.
Prepares all charges and recharges for furnace loading, including welding of hooks for overhead lifting.
Notifies appropriate personnel of low raw material levels as needed.
Orders raw materials (Revert, alloy and elements) as needed for production.
Maintains and monitors vacuum levels throughout melts according to PCC specifications.
Charges furnace by adding virgin or revert materials as required.
Takes sample of molten metal for lab analysis; makes calculations and adjusts the composition when out of range (using an alloy blending system).
Approves start of pouring process when heat composition meets specifications.
Enter pour programs for each work order to be poured on Master Heat.
Operates the Master Caster furnace to pour alloy ingots and large vacuum castings; operates hydraulic systems, doors, cranes and hoists.
Assembles air casting bottom pour ladles and trigger mechanisms.
Operates Air Master Melt furnace to pour alloy ingots and large castings; operates hydraulic systems, large overhead cranes and bottom pour ladles.
Slag, de‑ox and prepares air master melt heats in a variety of alloys for pouring into ingots and castings.
Pours test bar material to the casting specifications for each heat.
Rebuilds Master Caster bottom pour ladle systems, including backpacks, stopper rods, nozzles and hosts.
Weighs, marks and documents all heats correctly throughout the master melt process.
Maintains and monitors condition of melting coils, furnace linings, pouring ladles and equipment.
Cleans furnace of soot deposits.
Rebuilds vacuum ladles and backpack actuators.
Leak checks and repairs minor or major vacuum leaks.
Changes oil in diffusion and other pumps.
Troubleshoots mechanical and electrical failures on furnace systems.
Rebuilds burnout furnaces as needed.
Works with maintenance to perform preventative maintenance and repair the furnaces as needed.
Completes accurate logs, production reports and records.
Provides work direction, training, and working supervision as assigned.
Meets all production and quality standards.
Adheres to plant and department safety rules.
Safely operates all equipment and tools.
Identifies and reports safety problems.
Equipment, Vehicles, Tools And/Or Machinery Used
Air Master Melt Furnace
Master Caster Furnace
Burnout furnaces (for Air Casting and Vacuum Casting)
Pneumatic tools (e.g., air hammers, air chisels)
Forklift
Hoists
Overhead crane
Special lifting devices
Hydraulic presses
Electric rammer
Basic hand tools (e.g., wrenches, screwdrivers, prybars, etc.)
Torches (gas, air arc, arc welding)
Electric grinder
Linear actuators
Drill press
CB radios
Training
Training is provided on the job.
PCC's Forklift Driving Safety Certification Training must be completed.
Qualifications
Basic knowledge of vacuum and air master melt operations and vacuum furnace operations as demonstrated by competent performance of all Assistant Master Melt Vacuum Furnace Operator duties, or equivalent combination of experience and training.
Ability to read, interpret, and follow specifications on Technique Cards, Process Control Procedures and Standard Operating Procedures.
Ability to perform basic mathematical calculations (addition, subtraction, multiplication, division) and calculate percentages.
Ability to work independently and as a team member, with limited supervision.
Ability to provide work direction and coordinate the work of others.
Ability to communicate effectively, both verbally and in writing.
Physical ability to perform essential job functions.
Ability to use computer interfaces to enter master melt and casting data and build heat requirements.
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