AIST Steel Intern Scholarship
Kailee A. Frenn
This past summer, I had the pleasure of working as an engineering intern at Hodge Foundry Inc., in Greenville, Pa., USA. Hodge is a gray and ductile iron foundry unique for its capability of casting parts from 60,000 pounds upwards of 200,000 pounds, being the only foundry in North America capable of doing so. From the large scale of the equipment to the complexity and variety of the parts, I frequently found myself fascinated by the business. During my time at Hodge, I was able to delve into quality engineering related projects. In addition to learning about the sand-casting process I was able to apply some of the skills I learned in my freshman classes.
The main project I worked on this summer was a thorough quality report on two castings. The bulk of the project entailed constructing full dimensional reports for both parts which included 300+ measurements each. Due to the size and complexity of the parts as well as the reports, I had to go beyond the basic tools of measuring tapes and calipers. I constructed a 3D scan of point cloud data using a FaroArm® with a laser scanner attachment and the metrology software PolyWorks. This process required a great deal of attention to detail as well as patience and problem solving. The project also put my time management and communication skills to the test, allowing me to further develop my professional skills. After completing the scans and taking all the measurements digitally, I exercised my Excel skills as I constructed the detailed reports that would be presented to the customer. This project exposed me to the quality processes of Part Production Approval Process (PPAP) and First Article Inspection (FAI) which are integral to production of parts at high standards. By the end of my time with Hodge, I was able to meet with the other engineers and present them the information I learned from this project.
Another quality process I was involved in was sand and metal testing in the lab. I was able to support the quality department by regularly conducting the necessary sand testing which ensured the quality of the molds. I learned about cast iron’s microstructure and experienced the processes of testing its chemical and tensile properties.
Utilizing cutting edge technology in the setting of metal casting has granted me an opportunity to reflect on how far an industry may progress and the importance of innovation. My involvement in the quality processes at Hodge has opened my eyes to the importance and nuances of the field of quality engineering. My time at Hodge has also provided me with a great deal of experience to take back and apply to furthering my education and future career prospects.