All he could find was part-time work with Bon Apetit, the College’s food service provider. One year after joining his fellow seniors on Commencement Weekend for the Deans’ Breakfast, the former economics major/ math and Spanish minor found himself serving breakfast to a new crop of graduating seniors. “I guess you could say it was humbling, but it was work; I was glad to have it, and it felt good to be on campus again,” Carroll recalls.With that attitude he persevered, volunteered as an assistant baseball coach at a nearby high school, whose head coach was friends with the owners of Harrison Steel Castings in Attica. The coach recommended Carroll, and the timing was right. “They were looking for someone with skills like mine—an analyst—to look at the entire production process, the big picture.” Carroll went to work as the sole production analyst for the vice president of operations, learning each step of that process and studying how it might be improved. He calls the job a great fit for someone with a liberal
Shaping Metal with Computers and Mahogany: A mold for each casting is designed using CAD software, which directs the machine that cuts and routs mahogany boards. These are assembled into precisely shaped patterns . Simulation programs calculate the amount of metal to be used, where it will be poured into the mold, and where extra reservoirs need to be built into the mold to allow for the 4% contraction that occurs when the molten metal cools to a solid. Making the Mold: The wooden pattern is placed inside a steel flask , into which is poured silica/zircon sand mixed with chemicals and a bonding agent. The sand solidifies around the pattern within 10 minutes. With a melting temperature above 3,200 degrees, silica sand is the ideal material to hold the 2,800-degree molten metal.  Here a worker burns off alcohol in the wash coating on the top (cope) of a mold before it is joined to the bottom (drag) and molten metal is poured in. The coating prevents sand in the mold from attaching itself to the metal.
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