FOUNDRY OCCUPATIONS California Occupational Guide Number 37 Interest Area 5-C 1998
THE JOB
Metal units ranging in complexity from pipe-fittings to engine blocks are often produced by pouring molten metals into sand molds. This process is called casting. MOLDERS prepare the molds into which metal is transferred. When hollow castings are desired, COREMAKERS form cores which are placed inside molds before the metal is poured. PATTERNMAKERS fabricate the metal or wood shapes that give molds and cores the proper shape.
When an order comes to the foundry for a new casting, Patternmakers make a full-scale wooden or metal model of the object using engineering drawings as guides. Wood Patternmakers use saws, planers, drills, lathes, and various hand tools; in addition to these tools, metal Patternmakers use machine shop and tool room machines. After mixing the right proportions of sand and binding agents, Molders force the mixture around a pattern held in an open-ended container called a flask which forms a mold of the design when the pattern is removed. If the casting is to be hollow, Coremakers form a core from a mold with a similar mixture of sand and binding agents.
Though Molders, Coremakers, and Patternmakers perform routine tasks repeatedly, there is more variety in foundry work than in most industrial occupations. The journey-level worker makes many different types of molds, cores, and patterns, which requires skill and judgment to produce an acceptable product. Casting can be a difficult task because the materials are relatively crude, the tools and equipment simple, and the behavior of molten metal somewhat erratic. Since each metal and alloy cast has its own characteristics which affect molding techniques, foundry workers specialize in steel, iron, bronze, brass or aluminum.
WORKING CONDITIONS
Although foundry workers work with molten metal, powerful machinery, and heavy molds and cores, working conditions for these occupations do not differ significantly from those of other factories and plants. The only workers continuously exposed to the heat of molten metal are the melting crews. Workers may be annoyed by occasional smoke, heat or dust. Journey-level workers are less likely to be exposed than are Molder or Coremaker helpers.
Molders and Coremakers must be in good physical condition, because the work can involve considerable walking, standing, bending and lifting. There are intervals of light work, such as mold finishing and core setting. Because molten metals are used, protective clothing, gloves and other safety equipment are required when appropriate.
A pattern shop operates either as part of a foundry or as an independent operation producing patterns for different foundries. In either case, Patternmakers enjoy generally pleasant working environments; shops are generally quiet, well lit and ventilated but are subject to the noise of wood and metal working machines. The work is not physically demanding, though long periods of standing and some heavy lifting are necessary.
Patternmaking tools are generally supplied by the employee. Molders and Coremakers sometimes must buy their own tools. Tool costs may range between $100 to $200 for Molders and Coremakers, and may reach $1,000 or more for journey-level Patternmakers. Foundry workers may belong to the International Molders and Allied Workers Union, the United Foundry and Warehouse Employees, or the United Steel Workers of America. Patternmakers may belong to the Patternmaker's Association. Most foundries and patternmaking shops are located in urban areas.
EMPLOYMENT OUTLOOK
The following information is from the California Projections of Employment published by the Labor Market Information Division.
These figures represent the broad occupational group Foundry Mold, Core Makers, and Precision which includes Foundry occupations.
Estimated number of workers in 1993 830 Estimated number of workers in 2005 980 Projected Growth 1993-2005 18% Estimated openings due to separations by 2005 210
These figures represent the broad occupational group Molders, Shapers, excluding Jeweler which includes Foundry occupations.
Estimated number of workers in 1993 1,700 Estimated number of workers in 2005 1,760 Projected Growth 1993-2005 4% Estimated openings due to separations by 2005 390
These figures represent the broad occupational group Patternmakers, Model Makers, and Layout which includes Foundry occupations.
Estimated number of workers in 1993 310 Estimated number of workers in 2005 310 Projected Growth 1993-2005 0% Estimated openings due to separations by 2005 70
(These figures do not include self-employment or openings due to turnover.)
Automation of some casting procedures will limit future job opportunities in the foundries.
Openings caused by workers who leave the occupation will provide most of the job opportunities. The average age of foundry workers has increased over the past few years. As these workers retire, opportunities will be created for younger workers. Occasional shortages of journey-level workers develop when the demand for cast products is heavy.
Increasing, complex mechanization will give the skilled Molder and Coremaker an advantage when seeking work; unskilled and semiskilled workers will have a more difficult time finding work. Job openings can fluctuate because the demand for cast products is sensitive to economic changes.
Employment growth in patternmaking will be slow over the next few years because better and cheaper parts are now produced by modern machining methods, eliminating the need for castings. Therefore, fewer patterns will need to be made and maintained.
WAGES, HOURS, AND FRINGE BENEFITS
Precision Foundry Mold and Coremakers in California earn a median wage of $8.71 per hour. Apprentices and trainees usually receive minimum wage to start. The median wage for Precision Molders Shapers, Casters, and Carvers (except jewelry and foundry) is $10.51. The median wage for Precision Pattern Makers Model Makers, Lay-Out Workers, and Cutters is $7.94. Apprentices and trainees can start at minimum wage. The standard workweek is 40 hours, five days a week.
Busy shops may run two or three shifts; the night crews are usually paid a shift differential. Patternmakers generally work day shift only. Overtime is occasionally required, and paid at one and one-half the basic rate. Retirement benefits, medical and dental plans, and paid vacation and holidays are among the fringe benefits generally offered.
ENTRANCE REQUIREMENTS AND TRAINING
Employers seldom set specific educational requirements for applicants, but prefer high school graduates with a background in science, mathematics, shop courses, mechanical drawing, industrial engineering, or business. This preference applies especially to prospective Patternmakers.
Workers may get training either through an apprenticeship program or on the job. To enter an apprenticeship program, a person must be at least 18 years of age and employable by a foundry. Most apprentices start as helpers. Molders and Coremakers generally must complete a three- to four-year apprenticeship program, or its equivalent, to attain full journey-level status.
A five-year program, or equivalent experience, is necessary for the journey- level Patternmaker. When workers are trained on the job, the length of training depends on the complexity of the job.
ADVANCEMENT
Promotional opportunities exist for Molders, Coremakers and Patternmakers who know their job well and who have supervisory ability. Advancement to lead person, supervisor, and management is possible in many shops. Those who understand and can apply the procedures of metallurgy, sand testing and control, and can manage people, are the most likely to be promoted.
FINDING THE JOB
Inexperienced workers can best find work by applying directly to the employer. Persons with experience may also register with the California Employment Development Department Job Service, the appropriate union, or private employment agencies.
ADDITIONAL SOURCES OF INFORMATION
Glass Molders, Pottery and Plastic Union Local 164 8140 Baldwin Street Oakland, CA 94621 (510) 632-4774
Patternmakers Association of Los Angeles 214 South Loma Dr. Los Angeles, CA 90026 (213) 483-4533
American Foundrymen's Society 505 State Street Des Plaines, IL 60016-8399 (800) 537-4237 www.afsinc.org/
RELATED OCCUPATIONAL GUIDES
Tool and Die Makers No. 15
OCCUPATIONAL CODE REFERENCES
DOT (Dictionary of Occupational Titles, 4th Ed.,1991) Molder 518.361-010 Coremaker 518.381-014 Patternmaker, Metal 600.280-050 Patternmaker, Wood 661.281-022 Patternmaker, Metal, Bench 693.281-018
OES (Occupational Employment Statistics) System Foundry, Mold, Core Makers, Precision 899020 Molders, Shapers, Except Jewelry 899050 Patternmakers, Model Makers, Layout 899080
Source: State of California, Employment Development Department,
Labor Market Information Division, Information Services Group,
(916) 262-2162
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