Die Casting Process Engineer

General Motors•Bedford, IN

2d•Onsite

About The Position

The Die Casting Process Engineering Team excels in the development, testing, implementation and execution of new die casting programs, platforms and technology. This group works with 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.

Requirements

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 PFMEA’s 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

Nice To Haves

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

Responsibilities

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)