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Aluminum Foundry Process Engineer Jobs (NOW HIRING)

Neptune

Foundry Process Engineer

Tallassee, AL · On-site

The Foundry Process Engineer will be responsible for yielding improvement through the analysis of defective parts and processes throughout the foundry. Essential Responsibilities: Analyze, define ...

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Aluminum Foundry Process Engineer information

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$69.5K

$80.8K

$88.5K

How much do aluminum foundry process engineer jobs pay per year?

As of Sep 15, 2026, the average yearly pay for aluminum foundry process engineer in the United States is $80,833.00, according to ZipRecruiter salary data. Most workers in this role earn between $76,500.00 and $85,500.00 per year, depending on experience, location, and employer.

What does an aluminum foundry process engineer do?

An Aluminum Foundry Process Engineer is responsible for designing, optimizing, and overseeing the manufacturing processes involved in casting aluminum components. They work to improve product quality, increase efficiency, and ensure safety standards are met throughout the foundry. Their duties often include troubleshooting process issues, implementing new technologies, and collaborating with other engineers and production staff to meet production goals. This role is vital for maintaining cost-effective and high-quality aluminum production in industries such as automotive, aerospace, and manufacturing.

What are the key skills and qualifications needed to thrive as an aluminum foundry process engineer?

To excel as an Aluminum Foundry Process Engineer, a solid background in materials science or engineering, coupled with experience in metal casting and process optimization, is typically required. Familiarity with CAD software, simulation tools, and industry-specific quality management systems like ISO 9001 is important, along with relevant engineering certifications. Strong problem-solving abilities, attention to detail, and effective communication help professionals adapt to production challenges and collaborate with cross-functional teams. These skills ensure the efficient production of high-quality cast aluminum components while maintaining safety and cost-effectiveness.

What are some common challenges faced by aluminum foundry process engineers, and how can they be addressed?

Aluminum Foundry Process Engineers often encounter challenges such as maintaining consistent casting quality, optimizing process parameters, and minimizing defects like porosity or inclusions. Addressing these issues typically involves collaborating closely with production teams, conducting root cause analyses, and implementing process improvements based on data-driven insights. Regular communication with quality control and maintenance personnel is essential to ensure that process adjustments are effective and sustainable. Staying up-to-date with advancements in foundry technology and continuous training can also help engineers proactively tackle process inefficiencies.

What is the difference between Aluminum Foundry Process Engineer vs Aluminum Casting Technician?

AspectAluminum Foundry Process EngineerAluminum Casting Technician
CredentialsBachelor's degree in engineering or related fieldTechnical diploma or certification in casting or metallurgy
Work EnvironmentDesign, optimize, and oversee casting processes in manufacturing plantsOperate and maintain casting equipment on the shop floor
ResponsibilitiesProcess development, troubleshooting, quality control, process improvementSetup, operate, and monitor casting machinery, perform inspections

The Aluminum Foundry Process Engineer focuses on designing and improving casting processes, ensuring quality and efficiency. In contrast, the Aluminum Casting Technician handles the hands-on operation and maintenance of casting equipment. Both roles are essential in the aluminum casting industry but differ in scope, responsibilities, and required qualifications.

What are popular job titles related to Aluminum Foundry Process Engineer jobs?

For Aluminum Foundry Process Engineer jobs, the most frequently searched job titles are:

Infographic showing various Aluminum Foundry Process Engineer job openings in the United States as of September 2026, with employment types broken down into 1% As Needed, 77% Full Time, 18% Part Time, 3% Contract, and 1% Nights. Highlights an 89% Physical, 2% Hybrid, and 9% Remote job distribution, with an average salary of $80,833 per year, or $38.9 per hour.

Foundry Process Engineer

Manitowoc, WI

WISCONSIN ALUMINUM FOUNDRY CO INC
Manufacturing • 201 - 500 employees
Learn more about WISCONSIN ALUMINUM FOUNDRY CO INCexternal

Full-time

Posted 10 days ago

Wisconsin Aluminum Foundry rating

8.4

Company rating: 8.4 out of 10

Based on 5 frontline employees who took The Breakroom Quiz

Job description

FOUNDRY PROCESS ENGINEER

Wisconsin Aluminum Foundry | Manitowoc, WI

You don't become a great casting engineer by staying behind a desk.

At Wisconsin Aluminum Foundry, you'll be where the real engineering happens – on the production floor, at the process, solving problems that don't have easy answers.

You will develop casting processes for new products, troubleshoot existing jobs, dig into scrap and customer complaints, work alongside production leaders and operators, and use tools like MAGMASOFT, DOE, metallurgy principles, and process analysis to make a good process better. You will actually see the result of your work.

Your process becomes the casting.

WHAT YOU'LL OWN

As a Foundry Process Engineer, you'll help develop robust, repeatable, error-proof casting processes from new job startup through production.

You'll:

  • Develop new casting processes and bring new projects from concept into production
  • Solve problems at the source by investigating scrap, defects, and customer complaints
  • Work directly with production supervisors and managers during new job launches and troublesome jobs
  • Use MAGMASOFT simulation to troubleshoot and improve casting performance
  • Apply Design of Experiments (DOE) and structured problem-solving methods
  • Evaluate metallurgy, gating systems, casting design, and process parameters
  • Partner with Engineering to review simulations and identify opportunities to improve the process
  • Design, program, and troubleshoot pressure testing, qualification, and machining fixtures
  • Spend meaningful time on the production floor working with the people who run the process

This isn't an engineering role where you hand off your work and move on.

You own the problem until it's solved.

THIS MIGHT BE YOU IF…

You probably enjoy the kind of problem that makes everyone else say:

"Why is this happening?"

And your first thought is:

"Let's figure it out."

You'll fit well here if you:

  • Have a Bachelor's degree in Engineering or a related field
  • Have experience in an aluminum foundry, casting, or manufacturing environment
  • Understand metallurgy, gating systems, casting design, and process development
  • Are comfortable troubleshooting problems using data, technical analysis, and sound judgment
  • Can make decisions when the answer isn't sitting in a textbook
  • Communicate well with both engineers and people on the production floor
  • Work well across Engineering, Operations, Quality, and leadership
  • Know that the best solutions often come from getting close to the process

Experience with MAGMASOFT and SolidWorks is highly desirable.

WHY WAF?

For more than 115 years, Wisconsin Aluminum Foundry has been solving some of the toughest aluminum and copper-based casting challenges. Today, our engineers work with advanced casting technologies and integrated manufacturing capabilities to take products from engineering and prototyping through production.

But what makes WAF different isn't just the technology.

It's the people who refuse to settle for "good enough."

Here, your work doesn't disappear into a spreadsheet. You'll see your engineering decisions on the floor, in the process, and ultimately in the parts we ship to customers.

Stop looking for a job where you can make an impact.
 

Find one where you can see it.

Join WAF. Apply today.

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