|
Career Opportunities in the Metal Casting Industry
Most people in the casting industry have highly specialised
skills. Companies in the industry, therefore, recruit individuals
who have the kind of aptitude for specialised training which, sometimes,
can be lengthy. But for those who are successful in staying the course
it is one of the most satisfying and challenging businesses in the
manufacturing industry and one with exciting prospects.
Like any other production company a casting firm also needs its administrators;
financial people, personnel staff, sales and marketing specialists
and of course its management and supervisory staff.
The range of jobs is wide with opportunities for highly qualified
starters as well as for those whose academic qualifications are not
so high but who have the aptitude to learn practical skills.
There are openings at all levels for school leavers, graduates and
older people, who may be skilled or non-skilled. There are ample opportunities
for women as well as men to join all sectors of the industry from
production through to sales and marketing. There can be few industries
where there are so many opportunities to advance to the top levels
of management from any starting point within a company.
We describe below the many specialised jobs found in the casting
industry together with a guide to the educational and specialist qualifications
that may be needed and details of further education which may be necessary.
Different employees will have different policies on recruitment and
training procedures so this information should be treated as a general
guide.
Technologists
| Technicians | Craftsmen
| Process Operators
Management, Administration,
Marketing and Sales | How
to progress in the Casting Industry
Technologists
| ENTRY ROUTE |
ACADEMIC STANDARD |
FURTHER TRAINING |
| School leaver |
5 good grade GCSE’s
or equiv. preferably inc. maths, English and a science |
In-house 8 day
release to advance level followed by block release to study to
degree or equiv. standard |
| Older school leaver |
2 A levels or equiv |
Block release to study
to degree or equiv. standard |
| Graduate |
Science or eng. degree
or equiv. qualification |
Specialised according
to chosen discipline, management skills |
Technologists are the practical scientists of the industrial world.
In the casting industry they are found in many different areas with
their functions varying from basic research to applying the latest
technology to shop floor production.
They are needed in universities to undertake research in the sciences
applied to the casting industry, metals, melting reactions, control
and testing processes, etc. The products of their work fuel new developments
in the industry.
Suppliers of equipment and raw materials need them as do the industry
funded research establishments where they investigate, progress and
develop ways of applying new knowledge to production operations.
In the casting industry itself, the technologist category embraces
a whole range of specialists. Chemists, physicists, material scientists,
engineers, metallurgists and production engineers are just some of
them. A few of them are described here.
Mechanical Engineer
Mechanical engineers are employed to undertake many different functions
in casting companies from advising and assisting designers to running
plant maintenance departments or running quality assurance systems.
The specialist knowledge needed for each of these functions is quite
different but all demand that the engineer is able to apply complex
ideas and theories to practical situations. Their basic function is
often that of the problems solver applying particular knowledge to
such items as the selection or modification of plant or machinery,
planning and implementing complex installation or maintenance procedures,
Many engineers specialise after their initial training and two of
the most common choices are production engineering and designing.
Production Engineer
The function of production engineers is to plan the complex operations
which enable the company to manufacture its products in the most efficient
way. They need to apply modern planning methods; organise different
processes to fit together and if unexpected breakdowns are concerned
they must be able to change plans with the minimum of disruption and
down time.
Metallurgist
As might be expected metallurgists are involved with most aspects
of the metal casting business. They have to develop a high level of
knowledge about metals, their strengths and weaknesses, their resistance
to corrosion or to heat and how their structures and properties can
be changed. They also have to understand theoretical data, be able
to apply it to practical shop floor operations and communicate it
to non technical personnel.
They may be involved in the selection of alloys to suit particular
conditions specified by a customer, they could find themselves investigating
problems in production processes or researching new techniques. They
are often found advising the sales and marketing people and designers.
Metals are the life-blood of the industry and the metallurgist’s
main task is to ensure that they are of the right quality so that
finished castings comply with all aspects of the customers’ specification.
Designer
By collecting large amounts of relevant information and then starting
from a basic idea, designers are able to conceive the design of a
component to fulfil a customer’s specification. They have to
think very precisely, be able to solve problems quickly and efficiently
and they must be able to communicate effectively particularly when
describing the reasoning behind their designs to customers.
Castings designers, apart from an engineering degree need specialist
training in casting processes.
Technicians
| ENTRY ROUTE |
ACADEMIC
STANDARD |
FURTHER
TRAINING |
| School leaver |
3 good grades GCSE
or equiv. preferably inc. maths and the sciences |
In-house and college
of further education for specialised training |
There is a wide range of jobs that fall into this category, most
of which are related to the day to day technical control of production
processes to ensure that all the technical requirements made by the
customer are satisfied.
Technicians have to be good communicators for, invariably, their
jobs involve receiving and giving information to all levels of their
fellow employees, from operators and craftsmen to technologists and
managers. Very often their knowledge of the production processes leads
to promotion to supervisory or management posts. Sometimes technicians
are selected for courses of higher education, even to degree level
as part of their development into technologist positions.
The type and extent of the technicians’ job depends on the type
and size of the casting company but generally speaking the following
job descriptions are common in the industry. They are also the positions
that are commonly in demand.
Draughtsman
Computer aided design equipment has come to the aid of modern draughtsmen
but they still need to be familiar with the use of a range of drawing
instruments and techniques for their job is to produce the drawings
that act as guides and instructions to the production people.
Quality Controller / Inspector
These titles can cover a wide range of jobs involving inspection and
testing at any stage of the production process. Quality controllers
may also be employed in checking incoming raw materials, patterns,
moulds, cores, as well as finished or part finished castings.
They must be familiar with inspection documents and be able to carry
out a wide range of testing and measuring techniques and know how
to modify and improve products that are not up to standard.
Sand Technician
Essential materials in the casting industry are the sands that are
used for making the moulds. Choosing the correct type of sand for
the job is the sand technicians’ responsibility, They must have
a very good understanding of the sands that are used. They have to
know what their constituents are, what properties they possess in
terms of strength and texture. They have an important job and are
almost constantly on the shop floor making the decisions and the adjustments
to maintain sand quality.
Methods Engineer
These are the people who, among other tasks, calculate and design
the size and shape of the molten metal running systems to ensure that
sound castings are produced. They, therefore, need to understand how
different metals behave as they cool and solidify. They also need
to be expert in moulding techniques and materials to ensure that the
right shapes and quality of castings are consistently produced.
Chemist / Analytical Chemist / Laboratory Assistant
Most large foundries have their own chemical laboratories staffed
by these technicians. Most of the work is analysis to establish the
contents of alloys or raw materials. Most firms are now equipped with
the very latest automatic analytical apparatus but employees must
still have a broad understanding of ’hands on’ analytical
chemistry.
Estimator
The estimator’s decisions can make the difference between profit
and loss for a company. Based on drawings, information from their
colleagues and customers, coupled with a knowledge of the industry
and market pricing, estimators calculate the cost of producing castings,
to enable the company to determine a price for the customer.
Non Destructive Test Engineer
These technicians, as the title suggests, are responsible for carrying
out tests on castings to ensure that they are sound. A knowledge of
casting design and the properties of metals is essential to this job
as well as an understanding of casting drawings.
Mechanical Test Technician / Test House Technician
Once a casting is made the metal used has to be tested to check that
it has the physical properties required – this is where these
technicians come in. They test the materials in a wide variety of
ways. They may test its strength, its resistance to impact or check
its behaviour at different temperatures from below zero.
They need to know, therefore, how different metals act and how to
use the different testing apparatus.
Heat Treatment Technician / Furnace Technician
Many metals have to go through a heating and cooling cycle in a furnace
to give them the required properties. Heat treatment technicians identify
the type of treatment required and ensure the furnace is properly
controlled to give the required treatment. They need, then, to know
how metals change in these conditions and be able to measure the effects.
Radiographer
A radiographer in the casting industry is a specialist non destructive
test technician who specialises in taking x-ray photographs (radiographs)
of castings to ensure that they are sound, There are several types
of radiographic equipment and the radiographer must be familiar with
their use and especially how to place castings to ensure that the
most important areas are in view of the radiograph. Equally important
is being able to interpret the pictures so that faults can be identified.
Melting Technician
This job involves calculating the amounts of raw materials needed
to produce a particular alloy, deciding upon the sequence that they
should be added, and the temperature at which the alloy should be
cast. This position often involves working at the furnace, carrying
out checks and making necessary adjustments to ensure the molten metal
complies with specifications.
Metallurgic Technician
Although basically involved in assisting metallurgists in testing
and investigations, this technician’s job can vary depending
on the company and its facilities. It can involve taking and preparing
samples for examination under a microscope and carrying out laboratory
tests to determine properties of metals. These technicians, through
the knowledge they acquire, are often candidates to become technologists.
Craftsmen
| ENTRY ROUTE |
ACADEMIC
STANDARD |
FURTHER
TRAINING |
| School leaver |
Two to four good grade
GCSE’s or equiv. preferably inc. maths and a craft science |
In-house day release college
of further education |
The term craftsman is somewhat outdated, for there are many women
who are successfully employed in this category.
The craftsman has always been the holder of the expertise required
to make good castings and even today possesses the skills vital to
the production processes of many companies. The intimate knowledge
of casting processes put these people in a very good position to develop
their careers into management.
Today craft skills are essential not only for production processes
but also to the maintenance of plant and equipment so that no matter
what modern methods of production are applied or developed the particular
skills of the craftsmen will still be required.
Patternmaker
Patternmakers are creative – they are able to visualise a solid
shape in a flat drawing and then with their skills produce the initial
patterns that give castings their forms. Using shaping and cutting
equipment, they generally work in wood but sometimes metal or plastic
is used. Computer controlled equipment has now entered the pattermakers’
workshops although traditional hand finishing is still a requirement.
Patternmakers are employed by casting companies or specialist pattern
making firms.
Die Maker
People in this job also require the patternmakers’ skills. They
work usually in metals. They may have to work to even greater tolerances
and tend to use more computer controlled equipment. Dies are used
in investment casting and diecasting and diemakers may also undertake
work for shell moulding.
Moulder / Moulder Coremaker
Companies who specialise in castings that are too large, too complicated,
or are not repetitive enough to warrant being made on machines employ
these craftsmen to make moulds. They work with their hands producing
moulds from patterns and sometimes they assemble moulds from large
cores. Bench moulders produce moulds that are small enough to be lifted
by one person but use the same
Electrician
Casting companies employ electricians usually in maintenance departments
where they are involved in all types of electrical installation and
repair work. As more sophisticated equipment is being introduced into
the industry the electrician is finding more involvement in electronics.
Fitter / Maintenance Technician
This group of craftsmen is responsible for mechanical maintenance,
repair and installation of machinery and equipment. Their work is
very wide and varied and modern technology demands that they extend
their skills to cover hydraulics, pneumatics and robotics.
Process Operators
Entry Route
Process operator jobs are open to all age groups from the 16 year
old school leaver upwards. There are usually no entry requirements
in terms of examination results or other qualifications. Training
is normally provided by employers.
Employers have long recognised that academic achievements are not
necessarily a guide to how people can perform in a practical workplace.
Instead they look for aptitude, willingness and a positive attitude
to work. This does not mean that process operators carry a low level
of responsibility or importance in the industry. In fact in many cases
they are the key production people, especially where companies have
automated their operations.
Routes through to supervision and management positions are always
open to operators with the right kind of potential. The casting industry,
in fact, has traditionally looked to existing employees to fill its
supervisory needs and there are many examples of senior managers who
started their careers as process operators on the shop floor. >
Sand Mill Operator / Sand Mixer / Sand Man
They look after and operate the sand mixing machinery that produces
sands with different additions to produce the right mixture and quality
for the moulders. The actual duties vary, depending on the size and
type of equipment but some ability to identify an incorrect mix and
make the necessary adjustments is always required.
Cupola Attendant / Melter / Furnaceman
The industry uses many different types of furnaces for melting the
metals for their castings and these people are responsible for their
operations. Companies provide on-the job training.
Coremaker
Usually they operate machines very similar to moulding machines or
they could be involved in producing small cores from re-useable patterns.
All coremakers need to be able to recognise faults on the cores and
know how to put them right.
Shell Moulder / Shell Coremaker
These people operate the machines that produce shell moulds (see the
section How Metal is Cast). They are able to set and operate their
machines to make good quality moulds.
Wax Assembler
Steady hands are required for this delicate operation which entails
assembling wax shapes to make the complex wax pattern assemblies.
Care is needed because any marking of the patterns will affect the
final casting. Training is provided by employers.
Ceramic Moulder
After wax pattern assemblies are made they are dipped to give them
a ceramic coating that, when dried, becomes the mould. The operative
responsible is trained to understand the dipping/drying cycles and
to be familiar with the different ceramic coatings used.
Machine Moulder / Moulding Machine Operator
As well as operating the sand moulding machines these operators must
be able to recognise faults in the moulds and know how to repair them.
With larger machines they are often part of a larger team.
Ladleman / Caster / Shanker
These operators are responsible for transporting the molten metal
from the furnace and pouring it into the moulds. This can involve
large amounts of metal in ladles suspended from cranes down to small
containers (shanks) carried by hand. The job calls for good judgement
of distances, a steady eye and hand and an understanding of safety
precautions which are so vital when working with molten metals.
Die Caster
Die casters maintain and operate die casting machines. They are able
to make adjustments and additions to metals used, to recognise any
faults with castings and make, or advise on, the changes needed to
eliminate faults.
Burner / Radiac Operator / Arc Air Operator
These operators are all involved in the initial removal of surplus
metal from castings formed by the molten metal running systems, The
burner uses a high temperature flame, the Radiac Operator has a thin
grinding disc, while the Arc Air Operator uses an electric arc assisted
by an air blast.
Fettler / Grinder
When castings leave their moulds, they are not always the exact shapes
required. The fettlers and grinders, using abrasive wheels, grind
the surplus metal away to produce the accurate finished shapes. They
are trained to select, use and change the relevant grinding wheels
and are taught the precautions needed when using these machines.
Shot Blaster
Cleaning castings of surplus mould materials is often done with shot
blasting machines which direct streams of steel pellets at the castings.
Usually this is done automatically but sometimes an operator controls
the machines by hand either inside a large chamber or for smaller
castings, in an enclosed cabinet.
Welder
Using a variety of welding techniques they repair or sometimes assemble
castings. This job usually requires specialist training either in-house
or at a training centre. With the increasing demands for higher quality,
many welders are trained to achieve nationally recognised qualifications
moving them up to the craftsmen level.
Fork Lift Truck Driver
Fork lift trucks are used in many parts of the casting industry for
general lifting and carrying. They may operate in general stores,
for transporting castings on the shop floor or in the despatch department.
Drivers have to be careful and accurate operators with an ability
to judge distances, positions and weights of loads and develop an
awareness of the capabilities of their machines.
Crane Driver
Very often they operate from a cab high above the shop floor where
their ability to judge small distances from far away is critical,
especially when the load is a large container of molten metal. They
are trained to recognise colleagues hand signals and to be able to
operate their machines smoothly.
Slinger
Slingers are crane drivers’ mates and it is their job to fix
loads and indicate how they are to be moved. They are responsible
for selecting and attaching the correct lifting equipment to ensure
that the load does not slip or fall. Training is given by the company.
Management, Administration,
Marketing and Sales
Previously we have concentrated on jobs in the production side of
the casting industry. But as in any other manufacturing company the
production staff of a casting foundry has to be serviced. Raw materials
and machinery must be purchased, products must be sold and distributed,
people must be paid and insured and their safety and welfare must
be cared for. The firm must have good communications systems and its
fabric and contents must be secured. And overall, the company must
be efficiently managed.
All these services have to be manned and there is a constant demand
for people of the right calibre whether they be computer programmers,
salesmen or accountants, typists, personnel staff or general clerks.
Career paths to management can be long or short, depending on an
individual’s willingness to work and learn and the nature, size
and growth pattern of the company.
Most companies encourage and support their employees in obtaining
further qualifications through in-house training, day release or adult
education courses.
How to progress in the Casting
Industry
Please click on the image below to have a larger view presented.
File size = 156K so it will take a few minutes to download
Sandwell College of
Further and Higher Education - School of Engineering
Please contact us with the details of training courses
and seminars you provide |
