Die Casting Process Engineer

Job Description

The Die Casting Process Engineering Team excels in the development testing implementation and execution of new die casting programs platforms and technology. This group with our product engineering equipment engineers and plant teams to develop and launch high pressure die castings supporting General Motors entire portfolio including engine transmission drive unit and structural castings.

By working with a cross functional team of die casting engineers you will execute casting manufacturing projects by following a systematic engineering process of evaluation development validation and technology transfer leading into and supporting the launch of new die casting products. You will be responsible for working with product engineers and die OEMs on the process and tooling design reviewing and interpreting simulation results and process setup and startup on the plant floor.

Key job functions:

• Support Launch Wall process via Manufacturing Validations Build Plans PPAP and related engineering procedures
• Support testing and installations of equipment tooling and technologies both on and off site
• Lead support and present the analysis of casting defects
• Assist in process tooling and equipment testing troubleshooting and implementations
• Develop process documentation Process flow diagrams PCP PFMEA TIS and related technical documents as necessary for a program launch
• Analyze first time quality data and optimize processes using DOE Red X and related statistical tools
• Perform both Non and destructive testing procedures for casting investigation and analysis ( leak testing x ray CT thermal lab specimen prep chemistry density mechanical etc)
• On site work working on shop floor hands on equipment understanding of casting shop activity( climbing bending lifting in and around Hot aluminum)

• Demonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environment
• High Pressure Die Casting or similar tooling process quality or project management experience
• Functional knowledge of aluminum chemistry heat treat metallurgical processes
• Knowledge of process engineering procedures and disciplines such as PFMEAs and Process Control Plans
• Demonstrated understanding of mechanical concepts involving machine design process equipment tooling and secondary casting post processing
• Ability to work individually on specific programs yet collaboratively with Launch Team QC Design Tooling and other support groups
• Effective or functional knowledge of Magma Flow 3D simulation software

Preferred Experience:

• Training in aluminum metallurgy
• Prior manufacturing experience in high pressure die casting
• Training in flow simulations (Magma Flow 3d)

Education:

• BS degree (Engineering Metallurgy) or equivalent experience is required

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