Utility Core Maker

MISSION:

To fabricate ceramic cores via low pressure injection high pressure injection and invested core processes; to work independently to assure smooth product flow through all aspects of core production.

PRINCIPAL ACCOUNTABILITY:

Slurry Makeup and Testing:to make slurries within established process specifications.

• Essential Job Functions:
  • Many different slurries are used; checks pH viscosity temperature and gel times applies results to specification ranges and determines whether slurries are usable.
  • If needed modifies slurries to bring into specification without altering slurry with respect to core requirements.
  • Records time tracks work in progress.

Invested Core Processing:to fabricate acceptable ceramic cores by the Invested Core Process.

• Essential Job Functions
  • Inspects soluble for defects; decides on usability.
  • Assembles soluble patterns which differ for each core configuration; helps develop new assemble techniques.
  • Builds wax shell of assembled pattern.
  • Leaches soluble from wax shell.
  • Builds alpha coated core attending to surface quality stucco and adhesion before next layer is applied.
  • Fills remaining cavity with core pack.
  • De-waxes in hot wax tank and fires in furnace.
  • Records time tracks work in progress.

High Pressure Injection:to produce ceramic cores by high pressure injection molding.

• Essential Job Functions:
  • Operates high pressure machines per established process; monitors temperature and pressure.
  • Monitors inventory levels of high pressure ceramic mix and orders materials as needed.
  • Assists in the preparation of high-pressure ceramic mix.
  • Places green state cores in sand-filled trays transports trays

Low Pressure Injection:to produce ceramic cores by low pressure slurry injection molding.

• Essential Job Functions:
  • Operates low pressure machines per established process specifications to produce cores of acceptable quality.
  • Removes binder by using either flaming ovens or place under water as needed.
  • Records time; tracks work in progress; marks core I.D.

Plasma Spraying: to deposit a controlled thickness of a non-reactive coating material on the cores using plasma spraying.

• Essential Job Functions:
  • Sets up and operates plasma spray unit.
  • Applies uniform thickness by measuring cores before during and after plasma spraying.

Setter Production:to fabricate setters used as a firing fixture which directly influence the dimensional acceptability of ceramic cores.

• Essential Job Function:
  • Fabricates and reface setters by pouring slurry into mold cavity; removes binder; fires setters.

Core Repair:to repair ceramic cores after firing using established techniques.

• Essential Job Functions:
  
  
  • Inspects cores for surface defects flash positives and negatives and air pockets.
  • Repairs identified defects using established techniques.

Firing: to fire ceramic cores in furnace to increase strength and gain dimensional stability.

• Essential Job Functions:
  • Loads and unloads setters and product per PCC specifications.
  • Sets up and operates furnace per instructions.

Safety: to take responsibility for and demonstrate safe work practices.

• Essential Job Functions:
  • Adheres to plant and department safety rules.
  • Safely operates all equipment and tools.
  • Identifies and reports safety problems.
  • Wears all personal protective equipment as necessary.
  • May be required to work with hazardous waste.

OTHER DUTIES

• Performs minor maintenance on equipment as needed.
• Packages and ships product.
• Performs material testing as required.
• Completes all logs and records.
• Meets all production and quality standards.
• Performs other tasks as directed.

ESSENTIAL EQUIPMENT VEHICLES TOOLS AND/OR MACHINERY USED:

• Basic hand tools (e.g. wrenches sockets hammers etc.)
• Dimensional measuring tools (e.g. calipers micrometers gauges)
• furnace
• Injection Molding presses
• high shear mixer
• thermometer pH meter and viscosity cup
• forklift
• plasma spray unit
• slurry pots
• planetary mixer
• dryer ovens
• vacuum chambers
• leach tank
• knives and files
• hot wax tanks
• scales
• hoists
• pallet jacks
• hand grinders
• hand drills
• masonry band saws
• hot pencils

TRAINING

• On the job training is provided.
• PCCs Forklift Driving Safety Certification Training must be completed.
• May be required to complete hazardous waste management training.

QUALIFICATIONS

• Experience with ceramics or investing preferred.
• Ability to read and interpret Process Control Procedures Technique Cards and other technical specifications.
• Ability to work independently with minimal supervision.
• Ability to assess out-of-norm situations institute corrective actions and maintain production flow.
• Ability to perform basic mathematical calculations. (addition subtraction multiplication division)
• Ability to communicate effectively both verbally and in writing.
• Physical ability to lift and push