Metallurgical Intern

WAF | ALUMINUM ELEVATED

METALLURGICAL INTERN

Calling all Metallurgical Engineering, Materials Science/Engineering, or related fields! This project-based Summer 2027 internship will give you hands-on experience evaluating opportunities to improve molten metal controls and production testing at Wisconsin Aluminum Foundry.

PROJECT FOCUS AREAS

1. Thermal Analysis

Develop an understanding of thermal analysis for our aluminum alloys and evaluate whether it could be implemented as a routine production check. Determine what information the analysis can provide, how it correlates to current process controls and casting results, and what would be required to implement it in production.

2. Chemistry Optimization

Review current chemistry ranges and historical chemistry data, with particular focus on Fe/Mn relationships and balancing Mn/Fe where applicable. Evaluate whether tighter internal operating ranges or additional controls could improve consistency.

3. Portable Spectrometer Evaluation

Evaluate an Electronite portable spectrometer as a potential practical solution for WAF, including accuracy/repeatability, applications, limitations, ease of use, and comparison with existing spectrometer/testing methods.

WHAT YOU’LL GAIN

• Hands-on experience in a modern aluminum foundry environment
• Exposure to metallurgical testing, process controls, and production data
• Mentorship from experienced engineers 
• Experience evaluating industrial technology and making data-informed recommendations
• A meaningful engineering project with direct production relevance

THE END GOAL

By the end of the internship, provide recommendations on which technologies or controls would add value to our production process and what would be required to implement them.