Senior Materials Engineer (Metals, Forming & Castings)
In this role, you will:
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Lead failure investigations for metallic components across development, production, and field releases; execute mechanical testing and metallurgical characterization (SEM/EDS, metallography, fractography) to determine root cause and mitigations.
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Advise Design, Manufacturing, and Quality teams on metal selection, process capability, and process-induced failure modes for forming, stamping, and casting operations (DFMEA/PFMEA).
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Draft and maintain material and process specifications, quality acceptance criteria, and ASTM/ISO/SAE test procedures.
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Support supplier material and process qualification for formed, stamped, and cast metal components, including review of PPAP submissions and material certifications.
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Manage lab test plans, equipment calibration, SOPs, and safety standards while directing external vendor labs and mentoring junior engineers.
Qualifications
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Bachelor’s or Master’s degree in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related field.
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8+ years of experience in materials engineering, failure analysis, or metallurgical engineering, ideally in automotive, aerospace, or heavy equipment.
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Deep, hands-on expertise with metals across forming/stamping and casting processes, and their common failure modesDeep, hands-on expertise with metals across forming/stamping and casting processes, and their common failure modes as well as writing and reviewing processes.
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Strong experience with mechanical testing (Instron/UTM systems) and failure analysis techniques (fractography, SEM/EDS, metallography, hardness testing).
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Demonstrated track record independently leading root cause investigations and driving corrective actions to closure with cross-functional teams.
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Working knowledge of ASTM/ISO/SAE test standards and experience developing test specifications.
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Excellent written and verbal communication skills, with the ability to translate technical findings for non-materials audiences and leadership.
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Experience mentoring or directing the work of junior engineers or technicians.
Bonus Qualifications
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Experience with polymers, composites, adhesives/bonded joints, or coatings failure analysis.
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Familiarity with forming/stamping simulation tools (e.g., AutoForm, LS-DYNA), casting simulation, or DFMEA/PFMEA processes.
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Experience with supplier quality engineering, PPAP, or material certification review.
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Prior experience in high-volume automotive manufacturing or a vehicle development environment.
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Advanced degree (MS/PhD) in Materials Science or Metallurgy.