Casting Methoding Lead Engineer (Sand Castings)

About Immensa

The role

Responsibilities

• Design and review gating, risering, chilling, and core layouts for steel and alloy green-sand or no-bake castings.
• Run solidification simulations with MAGMASOFT, ProCAST, or equivalent and review supplier simulations and method cards.
• Investigate casting defects, identify root causes, and drive corrective action with foundries.
• Apply Oil & Gas casting standards, NDT acceptance criteria, and weld-repair limits.
• Audit and qualify foundries, create risk registers, and hold a technical position with supplier engineers and metallurgists.
• Review drawings, machining allowances, datums, critical tolerances, and inspection data; disposition non-conformances.
• Support costing, lead times, and on-time-in-full delivery for casting orders.

Required qualifications

• Bachelor’s degree in Mechanical, Manufacturing, Production, Foundry, or Metallurgical Engineering.
• At least 7 years designing methods for steel and alloy sand castings in a foundry or for a foundry supply base.
• Can run simulations using MAGMASOFT, ProCAST, or an equivalent tool.
• Track record of defect root-cause work with measurable results in rejection, yield, or weld-repair reduction.
• Working knowledge of Oil & Gas casting standards and NDT acceptance criteria.
• Foundry audit and qualification experience.
• Comfortable working across locations and time zones, with travel to suppliers.

Nice to have

• Experience with pump, valve, or impeller castings, including WCB, CF8M, CA6NM, or duplex alloys.
• Experience in NORSOK M-650 qualified foundries.
• Reverse engineering or spare-parts project experience.