M / Am, Primary Metal - Superalloys

Basic Details

Primary Role type (Technical, Executive or Managerial) =Technical

Job Grade =AC-L3C/D

Function

Production - ATL Primary Metals =Business Unit =Aerospace

Location =Lucknow

Reporting to (grade and Job Title) =Plant Head, ATL Primary Metals

Roles & Responsibilities

Key Responsibilities:

- Oversee day-to-day production activities related to the manufacturing of superalloys, ensuring adherence to production schedules and targets.
- Implement quality control measures to ensure that superalloy products meet required specifications and standards, including dimensional accuracy and material properties.
- Manage inventory levels of raw materials, intermediates, and finished products to support production requirements and minimize stockouts or excess inventory.
- Coordinate maintenance activities for production equipment to minimize downtime and ensure reliable operation.
- Liaise with suppliers to ensure timely delivery of raw materials and resolve any supply chain issues that may impact production.
- Monitor production performance metrics such as yield, scrap rate, and cycle time to track performance trends and identify areas for improvement.
- Handle the operation of the Vacuum Induction Melting machine efficiently as per SOP and defined parameters.
- Manage and optimize the melting process using high-temperature vacuum induction machine.
- Implement and monitor strict protocols for maintaining an inert or vacuum atmosphere during melting to prevent contamination.
- Collaborate with materials sourcing teams to ensure the procurement of high-quality raw materials necessary for superalloy manufacturing.
- Conduct assessments and make recommendations regarding the suitability of raw materials for achieving desired superalloy properties.
- Work closely with metallurgists and production head to adjust alloy compositions, ensuring precise control for meeting specific performance requirements.
- Oversee casting operations, ensuring the proper implementation of techniques such as investment casting or directional solidification.
- Monitor casting processes during VIM operation to eliminate impurities and ensure the development of a uniform microstructure during melting operation.
- Manage VIM operation procedures to achieve desired mechanical and metallurgical properties.
- Collaborate with machining teams to implement specialized tools and techniques suitable for the hardness and toughness of superalloys.
- Ensure compliance with quality and performance standards for superalloy components manufacturing processes in VIM operation.
- Implement and manage comprehensive quality control measures throughout the manufacturing process.
- Record results, parameters, and specifications of each iteration/Project at Superalloy manufacturing (in VIM) for NPD department.
- Participate in Root Cause Analysis (RCA) for critical NCRs to identify and address underlying
issues.
- Ensuring safe work environment within the working area.
- Ensuring continuous improvement (Kaizen) and 5S in respective areas

Education and Certifications:

- Bachelor's degree in Materials Science, Metallurgical Engineering, or related field (for Assistant Manager position).
- Master's degree preferred for Manager position.

**Experience**:

- 4-12 years of proven experience of handling production of Superalloy Ingots for any foundry or casting manufacturing industry.

Technical / Functional Expertise & other competencies:

- In-depth knowledge of superalloy metallurgy and materials science.
- Understanding of the vacuum arc melting process for both sponge and scrap routes.
- Knowledge and experience in overseeing ingot casting processes, including exploring and implementing various casting methods like directional solidification or continuous casting.
- Expertise in managing and optimizing HIP, Heat treatment processes, including annealing, solution treatment, and aging.
- Proficiency in implementing non-destructive testing methods to ensure ingot integrity.
- Strong organizational skills to maintain accurate records of processes, testing results, and quality control measures as per requirement of AS9100 standards along with basic understanding of ISO 9001/14001/45001.

Skills production of Superalloy