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Melting/Casting Metallurgist


  • HB Consultants LLC
  • 08/16/19
  • Decatur, AL
  • 35601
  • DOE / Yearly
  • Full-Time
Provide materials science and engineering technical support as required in process/product metallurgy for Raw Materials, Electric Arc Furnace (EAF), Ladle Metallurgy Furnace (LMF), and Continuous Caster. Work on product improvement initiatives and problem-solving projects as assigned in steel production facility. Use Structured Query Language (SQL) for historical data analysis of existing practices and identify process parameters to be controlled. Develop and optimize SOPs to minimize variability in steelmaking process and continuously improve quality management system. Develop mathematical models using MS Excel tools to assist operators in decision-making. Ensure manufactured steel and product designs meet customer requirements. Develop chemical/physical criteria to ensure products meet specifications. Ensure laboratory equipment used to measure steel and slag chemistry are calibrated and customer requirements are within tolerance of equipment. Operate and maintain analytical equipment including Optical Emission Spectrometer, Nitrogen and Carbon/Sulfur analyzer, and XRF slag analyzer for chemical analysis of steel and slag; and Optical microscope, Scanning Electron Microscope (SEM) and automatic polisher for microscopic analysis of steel and refractory. Provide metallurgical assistance to technical service representatives and customers as needed to resolve quality-related issues. Evaluate new opportunities and develop steel grades to satisfy customer requirements in technical support for Sales. Use chemical and microscopic analysis for inclusion and defect analysis. Develop alloy addition and refining practices for new steel grades using FACTSAGE and MS Office tools. Identify areas where procedures can be improved and enact appropriate changes. Identify areas for process and equipment functionality optimization and upgrades for increased production. Develop specific Melt Shop/Cast procedures to improve efficiency. Perform trials at EAF, LMF and Continuous Caster with new material (alloys, refractories and fluxes) or practices. Perform chemical analysis and inclusion analysis using SEM to determine trial results. Delegate metallurgical process changes to operators and maintenance personnel as needed. Provide ongoing training as required to teammates in steel making practices, new procedures and parameters. Prepare and deliver presentations to employees as required. Design and implement equipment modifications on Melt Shop/Cast mills to improve operations. Develop, engineer and implement quality improvement projects. Define end-use characteristics on new parts to ensure customer product needs are met. Evaluate new technology for economic impact and implement where economically advantageous. Evaluate steel chemistry to ensure that required physical properties are achieved.

JOB REQUIREMENTS
MINIMUM REQUIREMENTS: Must possess Masters or foreign equivalent degree in Materials Science / Engineering, Metallurgical Engg or directly related field, and 2 yrs experience in materials research and engineering, applying knowledge of steel making principles and experience in their application, in laboratory and industrial set-ups, including: steel / refractory sample preparation for chemical/microscopic analysis; experiments on steel for analysis of alloy addition effect on steel quality; using Optical Emission Spectrometer, Nitrogen and Carbon/Sulfur analyzer, and slag analyzer for chemical analysis of steel and slag; using Optical microscope, SEM and automatic polisher for microscopic analysis of steel and refractory; using FACTSAGE thermo-chemical software and MS Excel tools for thermodynamic modeling. Must have demonstrated experience working with industrial operators to collect steel, slag, refractory samples and data from LMF and Caster; instructing others in steelmaking practices; and preparing and delivering presentations to industry personnel.

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