- Ensure all metallurgical and material quality standards are followed consistently in the foundry.
- Oversee melting, alloying, casting, and heat treatment processes to achieve required metal properties.
- Perform charge calculations and control raw material mix for correct alloy composition.
- Monitor metal temperature, inoculation, and pouring practices to maintain casting quality.
- Check chemical composition of molten metal and castings using spectrometers and lab testing methods.
- Select, develop, and optimize alloys such as ductile iron, grey iron, carbon steel, and alloy steels based on application needs.
- Inspect and verify mechanical properties including strength, hardness, impact resistance, and microstructure.
- Conduct metallurgical testing including tensile, hardness, impact, and metallography analysis.
- Coordinate and monitor non-destructive testing such as ultrasonic, radiography, magnetic particle, and dye penetrant tests.
- Ensure castings and components meet customer drawings, specifications, and performance standards.
- Analyze casting defects such as porosity, shrinkage, cracks, inclusions, and sand-related issues.
- Perform root cause analysis and implement corrective and preventive actions to reduce scrap and rework.
- Develop and improve casting processes including gating, risering, and heat treatment cycles.
- Optimize foundry operations to improve yield, quality consistency, and production efficiency.
- Monitor process performance using quality tools such as SPC and FMEA.
- Ensure compliance with Indian and international standards such as IS, ASTM, ISO, IATF 16949, and railway requirements.
- Support customer audits, inspections, and certification processes.
- Maintain metallurgical records including test reports, material certificates, and quality documents.
- Work closely with production, engineering, maintenance, and quality teams to resolve technical issues.
- Provide technical guidance to shop-floor staff on metallurgical practices and defect prevention.
- Support new product development, trials, and prototype testing.
- Conduct failure analysis on rejected or field-returned components.
- Drive continuous improvement initiatives for cost reduction, quality improvement, and energy efficiency.
- Ensure all metallurgical operations follow safety, environmental, and regulatory guidelines.
- Research and introduce new materials, processes, and testing methods to improve product performance.
- Strong knowledge of foundry metallurgy, materials science, and casting processes.
- Expertise in ferrous and non-ferrous metals including SG iron, grey iron, carbon steel, and alloy steels.
- Deep understanding of alloy composition, charge calculation, chemical control, and solidification behavior.
- Hands-on experience in melting operations using induction furnaces and cupolas.
- Casting process control including inoculation, pouring practices, gating, risering, and mold systems (green sand, no-bake, investment casting).
- Strong skills in alloy selection, development, and performance optimization for automotive, railway, and engineering applications.
- In-depth knowledge of heat treatment processes such as annealing, normalizing, quenching, tempering, and austempering.
- Proficiency in metallurgical testing including chemical analysis (OES/XRF), tensile, hardness, impact, fatigue, and metallography.
- Expertise in sample preparation, etching, and microstructure evaluation using optical microscopy.
- Strong understanding of non-destructive testing methods including ultrasonic, radiography, magnetic particle, and dye penetrant inspection.
- Ability to identify casting and forging defects such as porosity, shrinkage, cracks, inclusions, and sand-related issues.
- Advanced root cause analysis skills using tools like 5-Why, Fishbone, 8D, FMEA, and CAPA.
- Strong knowledge of quality systems and standards including ISO 9001, IATF 16949, IS, ASTM, DIN, BIS, and railway specifications (RDSO).
- Proficiency in process monitoring, SPC, DOE, and continuous improvement methodologies.
- Experience in process optimization to improve yield, reduce scrap, and enhance consistency.
- Strong failure analysis and troubleshooting capability for production and field issues.
- Ability to read and interpret engineering drawings, material specifications, and customer requirements.
- Proficiency with metallurgical and inspection equipment such as spectrometers, UTM, hardness testers, microscopes, and basic CMM tools.
- Familiarity with casting simulation software and metallurgical analysis tools (preferred).
- Strong technical documentation and reporting skills for audits and customer submissions.
- High analytical thinking and data interpretation ability.
- Strong problem-solving and decision-making skills in production environments.
- Effective communication and cross-functional collaboration with production, quality, engineering, suppliers, and customers.
- Continuous improvement mindset with strong attention to detail and quality focus.
- Strong awareness of safety, environmental, and regulatory compliance in foundry operations.
Any Diploma / BE / ME / Relevant education in Metallurgical Engineering / Materials Science / Mechanical Engineering with Foundry / Metallurgy Focus. Certifications in Quality Management, NDT, Six Sigma, or Lean Manufacturing are desirable. Knowledge of automotive and railway quality standards such as IATF 16949, ISO 9001, ASTM, and EN standards is preferred. Priority will be given to candidates with foundry and metal casting industry knowledge related to Automobile Engineering, Railway Engineering, General Engineering, Agriculture Equipment, Heavy Engineering, Industrial Machinery, Defense and Aerospace, Manufacturing and Fabrication, and Material Processing.
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Whiteice Network, Foundry Metallurgy, Metallurgical Engineering, Metal Casting, Casting Processes, Foundry Operations, Melting Processes, Alloying Control, Solidification Behavior, Gating System Design, Risery Design, Heat Treatment Processes, Green Sand Molding, No-Bake Molding, Shell Molding, Investment Casting, Sand Casting, Permanent Mold Casting, Defect Prevention, Casting Quality Control, Metallurgical Quality Assurance, Quality Management Systems, ISO 9001 Compliance, IATF 16949 Standards, AS9100 Quality Systems, NADCAP Compliance, APQP Planning, PPAP Documentation, Customer Quality Requirements, Regulatory Compliance, Metallurgical Testing, Chemical Composition Analysis, Spectrographic Analysis (OES), XRF Testing, Microstructure Analysis, Metallography, Optical Microscopy, Tensile Testing, Hardness Testing, Impact Testing, Fatigue Testing, Non-Destructive Testing (NDT), Radiographic Testing (X-ray), Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), Dye Penetrant Testing (DPT), Failure Analysis, Root Cause Analysis, Defect Analysis, Porosity Control, Shrinkage Prevention, Inclusion Reduction, Crack Prevention, Statistical Process Control (SPC), Six Sigma Methodology, Lean Manufacturing, Design of Experiments (DOE), Continuous Improvement, Process Optimization, Scrap Reduction, Yield Improvement, Corrective Actions, Preventive Actions, CAPA Implementation, Process FMEA (PFMEA), Ferrous Metallurgy, Non-Ferrous Metallurgy, Cast Iron Metallurgy, Ductile Iron Processing, Grey Iron Casting, Steel Casting, Aluminum Alloy Casting, High-Strength Alloys, Alloy Development, Automotive Casting Components, Railway Casting Components, Engine Block Casting, Chassis Casting, Suspension Components, Bogies and Couplers, Material Property Control, Mechanical Strength Optimization, Fatigue Resistance, Wear Resistance, Impact Toughness, Carbon Equivalent Control, Inoculation Techniques, Magnesium Treatment, Graphite Nodule Formation, Graphite Flake Structure, Pearlite Microstructure, Ferrite Structure, Martensite Formation, Austenite Phase, Nucleation Control, Dendritic Growth, Eutectic Solidification, Cupola Furnace Operation, Induction Furnace Melting, Ladle Metallurgy, Slag Control, Degassing Techniques, Cold Shut Prevention, Hot Tear Control, Blowhole Defect Control, Misrun Prevention, Sand Wash Defects, Charge Calculation, Temperature Control, Melt Quality Control, Process Control Charts, Control Plans, Standard Operating Procedures, Metallurgical Documentation, Material Test Reports, Certificate of Analysis, Inspection Planning, Quality Audits, Supplier Metallurgy Evaluation, Casting Simulation Basics, Process Stability
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