Metal annealer

Metal annealers operate electric or gas kilns to soften metal so it can be cut and shaped more easily. They heat the metal to a specific temperature and / or colour and then slowly cool it, both according to specifications. Metal annealers inspect the metals through the entire process to observe any flaws.

A metal annealer typically does the following:

• Cleans oxides and scale from parts or fittings, using steam spray or immersing parts in chemical and water baths.
• Signals forklift operator to deposit or extract containers of parts into and from furnaces and quenching rinse tanks.
• Tests parts for hardness, using hardness testing equipment, and stamps heat treatment identification mark on part, using hammer and punch.
• Examines parts to ensure metal shade and color conform to specifications, utilizing knowledge of metal heat-treating.
• Removes parts from furnace after specified time and air dries or cools parts in water or oil brine or other baths.
• Reduces heat and allows parts to cool in furnace.
• Positions part in fixture, presses buttons to light burners and tends flame hardening machine, according to procedures, to case-harden metal part.
• Adjusts speed and operates continuous furnace through which parts are passed by means of reels and conveyors.
• Sets up and operates die-quenching machine to prevent parts from warping.
• Reads production schedule to determine processing sequence and furnace temperature requirements for objects to be heat treated.
• Activates and tends electric furnace that anneals base sections of hardened parts for subsequent machining.
• Sets automatic controls, observes gauges, and operates gas or electric furnace used to harden temper, or anneal metal parts.
• Loads parts into containers, closes furnace door, and inserts parts into furnace when specified temperature is reached.
• Covers parts with charcoal before inserting in furnace to prevent discoloration caused by rapid heating.

The following job titles also refer to metal annealer:

metal annealing worker
annealing kiln worker
annealing kiln operator
metal annealing process worker
heat treatment operator
metal annealing operative
metal annealing process operative
annealing operator

High school diploma is generally required to work as metal annealer. However, this requirement may differ in some countries.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Metal annealer is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to metal annealer.

glass annealer
mineral crushing operator
kiln firer
drawing kiln operator
pultrusion machine operator

These occupations require some skills and knowledge of metal annealer. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of metal annealer with a significant experience and/or extensive training.

automated assembly line operator
plastic and rubber products manufacturing supervisor
pulp control operator
industrial robot controller
gas station operator

This knowledge should be acquired through learning to fulfill the role of metal annealer.

• Metal forming technologies: The variety of technologies and techniques, such as forging, pressing, stamping, rolling and others, used for the forming processes of metal product manufacturing.
• Quality standards: The national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.

These skills are necessary for the role of metal annealer.

• Adjust burner controls: Adjust the heat in the burner regulating the thermostat according to the prescribed temperature following each product specification.
• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Observe products’ behaviour: Observe the color of fires and pyrometric cones under certain processing conditions such as high temperature.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Use personal protection equipment: Make use of protection equipment according to training, instruction and manuals. Inspect the equipment and use it consistently.
• Monitor automated machines: Continuously check up on the automated machine’s set-up and execution or make regular control rounds. If necessary, record and interpret data on the operating conditions of installations and equipment in order to identify abnormalities.
• Operate metal heating equipment: Use heating machinery to bake filled-up moulds or to melt steel, metal and other materials.
• Restore trays: Restore the trays in order to be reused by removing them form the kiln and placing them into the lehr for gradual cooling and annealing.
• Supply machine: Ensure the machine is fed the necessary and adequate materials and control the placement or automatic feed and retrieval of work pieces in the machines or machine tools on the production line.
• Consult technical resources: Read and interpret technical resources such as digital or paper drawings and adjustment data in order to properly set up a machine or working tool, or to assemble mechanical equipment.
• Adjust oven temperature: Adjust the oven temperature level and uniformity by correcting the fuel feed.
• Heat metals: Heat steel and metals in fire; adjust and regulate heat controls to reach appropriate pouring temperature.
• Follow production schedule: Follow production schedule taking into account all requirements, times and needs. This schedule outlines what individual commodities must be produced in each time period and encapsulates various concerns like production, staffing, inventory, etc. It is usually linked to manufacturing where the plan indicates when and how much of each product will be demanded. Utilise all the information in the actual implementation of the plan.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Set up the controller of a machine: Set up and give commands to a machine by dispatching the appropriate data and input into the (computer) controller corresponding with the desired processed product.

This knowledge is sometimes, but not always, required for the role of metal annealer. However, mastering this knowledge allows you to have more opportunities for career development.

• Mechanics: Theoretical and practical applications of the science studying the action of displacements and forces on physical bodies to the development of machinery and mechanical devices.

These skills and competences are sometimes, but not always, required for the role of metal annealer. However, mastering these skills and competences allows you to have more opportunities for career development.

• Read gas meter: Read gas measuring meter, recording the relevant information such as the amounts of gas dispensed and received.
• Assemble metal parts: Align and arrange steel and metal parts in order to assemble complete products; use the appropriate hand tools and gauges.
• Monitor gauge: Oversee the data presented by a gauge concerning the measurement of pressure, temperature, thickness of a material, and others.
• Remove defective products: Remove defective materials from the production line.
• Perform test run: Perform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, and adjust settings accordingly.
• Repair metal sheets: Repair bent or torn sheet metal.
• Perform kiln maintenance: Perform small maintenance tasks on drawing kiln such as replacing the cooling pads of the jacket and plugging in the kiln with mortar.
• Maintain equipment: Regularly inspect and perform all required activities to maintain the equipment in functional order prior or after its use.
• Monitor conveyor belt: Monitor the flow of the work pieces on the conveyor belt as they are processed by the machine to ensure optimal productivity.
• Manage waste: Manage or dispose of significant amounts of waste materials or hazardous materials. Ensure required licenses and permits are in place and reasonable management practices, industry standards, or commonly accepted farming practices followed.
• Operate drying blowers: Operate the portable air and heat blowers by placing them in the drying aisles in order to dry specific products.
• Mark a metal workpiece using punch: Handle and operate a punch and hammer to mark a metal work piece, for example for the purpose of carving a serial number, or for drilling to mark the exact place where a the hole should be places in order to keep the drill steady.
• Report defective manufacturing materials: Maintain required company records and forms in order to report any defective materials or questionable conditions of manufacturing machinery and equipment.
• Monitor end-product drying process: Let the end-products to cool and dry during the correct amount of time. If necessary, hasten the drying process using kilns or delay it by allowing water to humidify the products.
• Record production data: Keep a record of data such as name, colour and quantity of the produced goods.
• Manage kiln ventilation: Managing a product specific and energy efficient kiln ventilation.
• Handle metal work orders: Interpret work orders in order to determine which metal parts should be produced.

8121 – Metal processing plant operators

---

References

1. ESCO
2. Heat Treating, Annealing, and Tempering Machine Operator and Tender, Metal and Plastic Job Description, Duties and Jobs – CareerPlanner.com