Die Casting Process Engineer

Die Casting Process EngineerThe Die Casting Process Engineering Team excels in the development, testing, implementation and execution of new die casting programs, platforms and technology. This group with our 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.Key job functions:Support Launch Wall process via Manufacturing Validations, Build Plans, PPAP and related engineering proceduresSupport testing and installations of equipment, tooling and technologies both on and off siteLead, support and present the analysis of casting defectsAssist in process, tooling and equipment testing, troubleshooting and implementationsDevelop process documentation, Process flow diagrams, PCP, PFMEA, TIS, and related technical documents as necessary for a program launchAnalyze first time quality data and optimize processes using DOE, Red X, and related statistical toolsPerform 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)Basic QualificationsDemonstrated knowledge of foundry processes and ability to apply casting concepts in a manufacturing environmentHigh Pressure Die Casting, or similar tooling, process, quality, or project management experienceFunctional knowledge of aluminum chemistry, heat treat, metallurgical processesKnowledge of process engineering procedures and disciplines such as PFMEA's and Process Control PlansDemonstrated understanding of mechanical concepts involving machine design, process equipment, tooling, and secondary casting post processingAbility to work individually on specific programs yet collaboratively with Launch Team, QC, Design, Tooling, and other support groupsEffective or functional knowledge of Magma, Flow 3D, simulation softwarePreferred Experience:Training in aluminum metallurgyPrior manufacturing experience in high pressure die castingTraining in flow simulations (Magma, Flow 3d)Education:BS degree (Engineering, Metallurgy) or equivalent experience is requiredGM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc).This role is categorized as onsite. This means the selected candidate is expected to report to a specific location on a full-time basis. The selected candidate will be required to travel <25% for this role. This job may be eligible for relocation benefits.