Melter

PCC Talent Acquisition Portal•New Hartford, NY

8d•Onsite

About The Position

The Melter is responsible for preparing, charging, and operating consumable electrode vacuum melting furnaces and vacuum induction melting furnaces. This role involves precise calculations, material handling, and close monitoring of the melting process to ensure adherence to established procedures and quality standards.

Requirements

Ability to lift 35 pounds.
Ability to push/pull 50 lbs.
Ability to bend and squat at least 10 times per hour.
Ability to wear respiratory protection.
Ability to climb stairs and ladders.
Ability to operate all overhead cranes.
Ability to operate forklifts.
Proficiency with Vacuum Induction Melting Furnace, including evacuation system, power system, and control panels.
Proficiency with Consumable Electrode Vacuum Melting Furnace.
Proficiency with leak detection equipment.
Proficiency with crucibles, bell jars, molds, stools, and tundishes.
Proficiency with pendant and remote controlled cranes.
Proficiency with forklift trucks.
Proficiency with annealing furnace.
Proficiency with grit blast equipment.
Proficiency with Crucible Blasters – VAR Department.
Proficiency with scales, torque wrench, vacuum cleaner, and hand tools.
Proficiency with slings, tongs, chains, etc.
Proficiency with Oxygen & Acetylene Torch and Cleaning Heating Torches.
Proficiency with blanks, pneumatic wire brush, grinders, and wrenches.
Proficiency with levels and pie tape.
Proficiency with pneumatic hammer.
Proficiency with PPE.
Proficiency with remote controlled cranes.
Proficiency with cleaning equipment and head cleaning tools.
Proficiency with annulus balls.
Knowledge of materials including scrap, alloy steel electrode & ingots, ingots, stingers, inert gases, water, compressed air, stubs to make stinger maintenance welds, refractories, hot tops, insulating material, and solvents.
Ability to receive melt schedule and melt sheets.

Nice To Haves

May assist maintenance personnel.

Responsibilities

Prepare, charge, and operate consumable electrode vacuum melting furnaces and vacuum induction melting furnaces.
Calculate the rate of electrode travel.
Weigh electrodes using overhead cranes or calibrated scales.
Measure electrode length, slot length, and check material and heat number.
Prepare crucibles and stools using blasters, wire brushes, etc.
Prepare mating surfaces of stool, crucible, and furnace by cleaning and applying vacuum grease to seals.
Select proper crucible and stool, clean and place the crucible in the staging area, and set up the furnace for melting.
Remove crucible and ingot from the furnace, remove ingot from the crucible, weigh ingot, stamp ingot for identification, measure ingot length, and place ingot and bell jar using a floor-operated crane.
Operate the furnace, maintaining arc and controlling melting according to established procedures.
Make corrective additions as necessary.
Operate vacuum pumps and introduce inert gases as needed.
Check previously prepared charges to ensure the correct number of containers of scrap and alloying ingredients are available.
Place the charge in the crucible and launders.
Set stools, molds, and tundishes in the pouring chamber.
Close and seal the furnace chamber.
Operate and closely direct the operation of all controls (vacuum, power, temperature, etc.) throughout the melting cycle according to standard melt practices and procedures.
Take samples of molten metal as required and directed by the melt sheet, cutting and delivering samples to the laboratory.
Operate controls to tilt the furnace during pouring and index tundishes or mold tables during pouring.
Place launders in or out of the melt chamber.
Clean and prepare sample takers for use.
Check the flow of cooling water when necessary.
Clean the interior of the furnace.
Pour for proper rate of pour and proper filling of molds.
Post melt records, including all required data.
Open furnaces and remove molds.
Strip molds and hot tops, identify and weigh electrodes, and load electrodes onto the table.
Place molds in the oven for preheating.
Check the condition of stools and send for repair if necessary.
Close and bolt the vacuum chamber.
Wipe and/or brush ingots.
Shut down at the end of the melt cycle, and disassemble the furnace and remove the ingot.
Strip, weigh, and identify electrodes.
Make minor repairs.
Operate pendant/remote controlled cranes or fork trucks to move charges, materials, or supplies throughout the area.
Break up and remove refractory linings in the crucible.
Assemble prepared molds and stools.
Operate Crucible blaster to clean VAR Crucibles.
Report any malfunctions or abnormal operating conditions to the supervisor.
Maintain a clean and orderly work area.
Assist maintenance personnel as needed.
Prepare stuck electrodes for extraction by grinding, cutting, torching, etc.
Extract stuck electrodes.
Make slag charges per procedure.
Melt slag and pour per procedure.
Follow all procedures, SWIs, and additional training documents associated with the Melter Classification.