Laboratory Notebook No. LN-2214 · Property of Deccan Alloys Pvt. Ltd. Page 47

Victor Von Doom

SUBJECT: Career record · metallurgical engineering · ferrous & Al castings
LOCATION: Pune, Maharashtra PHONE: +91 20 555 0142 EMAIL: victor.vondoom@example.com WEB: victorvondoom.example.com
Purpose of record

I have spent 11 years moving cast and heat-treated parts from "rejected" to "shipped", mostly by reading fracture surfaces before reading reports. My last foundry line went from 7.8% to 2.1% scrap in 14 months. Entries below are dated and witnessed, as habit demands.

ENTRY No. 12 DATE: 03 Mar 2020 – present LOCATION: Chakan, Pune

Deccan Alloys Pvt. Ltd.

Senior Metallurgical Engineer, Foundry Quality

  • Cut scrap on the SG iron line from 7.8% to 2.1% by tightening Mg treatment windows and adding in-stream thermal analysis at 3 pouring stations.
  • Requalified 2 ladle refractory suppliers after spectrographic drift; sulfur pickup fell from 0.014% to 0.008% avg over 220 heats.
  • Wrote the plant's failure-analysis SOP (28 pages); fractography turnaround dropped from 9 days to 2.
Observed data · SG iron line, FY 2023–24
Heat batchNodularity %Mg residual %UTS MPaDisposition
H-4471910.042512Accept
H-4472880.038498Accept
H-4479740.026441Reject · fade
H-4483930.045521Accept

H-4479: 22 min ladle hold. Told them. Twice.

Conclusion

Mg fade past 15 minutes of ladle hold is the dominant reject cause on this line. Hold-time cap written into the pouring standard, 12 min max. Scrap has stayed under 2.5% for 14 consecutive months since.

J. Von DoomRecorded by · 14 Jun 2026
S. DatarRead & understood by · 15 Jun 2026
continued on page 48 →
Laboratory Notebook No. LN-2214 · Property of Deccan Alloys Pvt. Ltd. Page 48
ENTRY No. 11 DATE: Jul 2016 – Feb 2020 LOCATION: Bhosari, Pune

Mula Forge & Heat Treat Co.

Metallurgist, Heat Treatment Cell

  • Ran quench-and-temper qualification for 42CrMo4 axle forgings; core hardness spread narrowed from ±4.5 HRC to ±1.8 HRC across 6 furnace loads.
  • Traced a recurring quench-crack cluster to a 40 °C cold spot in polymer quenchant agitation; rework cost down INR 18 lakh/yr.
Graph 48-A · Jominy end-quench, 42CrMo4, heats E-201 vs E-207
HRC 60 45 30 Distance from quenched end, mm 0 25 50 E-201 (0.41% C) E-207 (0.38% C)
Plotted 12 Aug 2018. E-207 falls below 45 HRC at J=14 mm; spec floor is J=18 mm. Heat diverted to non-critical stock.
J. Von DoomRecorded by · 12 Aug 2018
A. PhadkeWitnessed by · 13 Aug 2018
ENTRY No. 10 DATE: Jun 2014 – Jun 2016 LOCATION: Pimpri, Pune

Sahyadri Castings Ltd.

Graduate Engineer Trainee, Melt Shop

  • Logged 1,400+ spectrometer readings and built the shop's first heat-chemistry archive in a shared spreadsheet; retrieval time went from "ask Deshmukh" to under 2 minutes.
  • Assisted charge calculation for A356 aluminum; melt loss held at 3.2% against a 4.5% budget.
ENTRY No. 9 REF: qualifications & apparatus

Education

  • B.Tech, Metallurgical & Materials Engineering · Vishrambag Institute of Technology, Pune · 2010–2014 · CGPA 8.6/10
  • Certified Six Sigma Green Belt, 2019 (project: gating redesign, yield +6.3%)

Apparatus & methods in regular use

Optical metallography SEM fractography OES spectrometry Jominy testing Thermal analysis (CE meter) MAGMASOFT basics Minitab IATF 16949 audits
Standing conclusion

Most casting defects announce themselves in the chemistry log two shifts before they appear on the shop floor. Keep the log, date it, and have someone sign it.

J. Von DoomRecorded by · 14 Jun 2026
S. DatarWitnessed by · 15 Jun 2026
index of entries: inside back cover