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Career In Foundry And Casting

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.

In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.

The word casting means shaping the materials. The factory where the metals are casted is called Foundry. The metals like grey iron, steel, non ferrous and malleable are melted, moulded and cooled to get the shape. Metal alloys, machinery, machinery equipments and tools, metal treatments, metal pipes, metal additions like metal nuggets, air plane’s turbine blades, axles etc are few of the products of foundry.


WHAT DO THEY DO?

A foundry specializes in producing metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools.


REQUIREMENTS:

There are various requirements for person working in Foundry and Casting is that they need to fulfil to pursue a career in the same. The requirements are classified under three heads –

EDUCATIONAL AND GENERAL QUALIFICATIONS:

Diploma, Bachelor and Master degrees in technology are the major courses of the stream. For Diploma and Bachelor degrees, the academic eligibility criterion is passing in 10 + 2. The Bachelor degree is the eligibility for the Master Degree. The higher studies, Ph.D. in the stream, can be pursued after the Master Degree. For all these courses, the admission process includes the entrance exam.

The major recruiting sectors of the field are automotive factories, auto component manufacturer industries, metal equipment related factories, construction equipment production companies and other foundries.

The chief job titles of the field are:

  • Metallurgist

  • Sales engineer

  • Foundry manager/supervisor

  • Induction melter

  • Convertor operator

  • Quality control supervisor

  • Production Engineer/ Manager

  • Technician

  • Plant head

  • Pattern maker

  • Draughtsman

  • Solid modeler

Apart from the offered job, one can have the own entrepreneur or factory. The major consumers of the castings are auto, agricultural, sanitary, earthmoving, pump and compressors, valves, diesel engines, electrical equipment, machine tools, industrial m/c, pipes and fittings, railways and power.

Teaching in the related colleges is also good option. Master Degree and Ph.D. holders are often appointed as lecturers or Professors in the colleges.

SKILLS

· Monitoring - Monitoring/Assessing performance of yourself, other individuals, or organizations to make improvements or take corrective action.

· Critical Thinking - Using logic and reasoning to identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems.

· Judgment and Decision Making - Considering the relative costs and benefits of potential actions to choose the most appropriate one.

· Time Management - Managing one's own time and the time of others.

· Operation Monitoring - Watching gauges, dials, or other indicators to make sure a machine is working properly.

· Active Listening - Giving full attention to what other people are saying, taking time to understand the points being made, asking questions as appropriate, and not interrupting at inappropriate times.

· Speaking - Talking to others to convey information effectively.

· Complex Problem Solving - Identifying complex problems and reviewing related information to develop and evaluate options and implement solutions.

· Operation and Control - Controlling operations of equipment or systems.

· Quality Control Analysis - Conducting tests and inspections of products, services, or processes to evaluate quality or performance.

· Coordination - Adjusting actions in relation to others' actions.

KNOWLEDGE

· Production and Processing - Knowledge of raw materials, production processes, quality control, costs, and other techniques for maximizing the effective manufacture and distribution of goods.

· English Language - Knowledge of the structure and content of the English language including the meaning and spelling of words, rules of composition, and grammar.

· Administration and Management - Knowledge of business and management principles involved in strategic planning, resource allocation, human resources modeling, leadership technique, production methods, and coordination of people and resources.

· Mechanical - Knowledge of machines and tools, including their designs, uses, repair, and maintenance.

· Public Safety and Security - Knowledge of relevant equipment, policies, procedures, and strategies to promote effective local, state, or national security operations for the protection of people, data, property, and institutions.

· Mathematics - Knowledge of arithmetic, algebra, geometry, calculus, statistics, and their applications.

· Education and Training - Knowledge of principles and methods for curriculum and training design, teaching and instruction for individuals and groups, and the measurement of training effects.

SALARY:

The initial pay to a fresh graduate is expected around Rs. 20,000 per month. The experienced is offered more.

JOB OUTLOOK:

The core job roles of the engineer are:

  • To oversee the foundry operations

  • Be responsible for the clients coordination

  • Ensuring appropriate product manufacturing process

  • Record management

  • Personnel management

  • Inspection of Die pre loading etc.

· Attention to Detail - Job requires being careful about detail and thorough in completing work tasks.

· Initiative - Job requires a willingness to take on responsibilities and challenges.

· Cooperation - Job requires being pleasant with others on the job and displaying a good-natured, cooperative attitude.

· Dependability - Job requires being reliable, responsible, and dependable, and fulfilling obligations.

· Self Control - Job requires maintaining composure, keeping emotions in check, controlling anger, and avoiding aggressive behavior, even in very difficult situations.

· Persistence - Job requires persistence in the face of obstacles.

· Integrity - Job requires being honest and ethical.

· Achievement/Effort - Job requires establishing and maintaining personally challenging achievement goals and exerting effort toward mastering tasks.

· Independence - Job requires developing one's own ways of doing things, guiding oneself with little or no supervision, and depending on oneself to get things done.

· Adaptability/Flexibility - Job requires being open to change (positive or negative) and to considerable variety in the workplace.

· Stress Tolerance - Job requires accepting criticism and dealing calmly and effectively with high stress situations.

· Analytical Thinking - Job requires analyzing information and using logic to address work-related issues and problems.

· Social Orientation - Job requires preferring to work with others rather than alone, and being personally connected with others on the job.

· Leadership - Job requires a willingness to lead, take charge, and offer opinions and direction.

· Innovation - Job requires creativity and alternative thinking to develop new ideas for and answers to work-related problems.

· Concern for Others - Job requires being sensitive to others' needs and feelings and being understanding and helpful on the job.

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