Senior Metallurgist – Alloy Design & Advanced Manufacturing

Description   Are you interested in designing and developing new alloys for demanding applications? Do you have experience leveraging metallurgy to understand how composition and processing control material performance? Are you interested in translating new alloy concepts into manufacturable materials using conventional and advanced manufacturing processes? We are seeking a Senior Metallurgist – Alloy Design & Advanced Manufacturing to lead the design, processing, and characterization of novel metals.

This role will combine computational thermodynamics, experimental alloy development, and advanced manufacturing to develop materials tailored to specific performance and manufacturing requirements. You will work across the full materials development cycle: from defining alloy compositions and processing windows through manufacturing, heat treatment, characterization, and performance evaluation. As a Senior Metallurgist – Alloy Design & Advanced Manufacturing, you will… Develop processing strategies for conventional and additive manufacturing Develop processing plans that connect alloy composition, solidification, thermomechanical processing, and heat treatment to desired microstructures and properties.

Design and evaluate alloys for additive manufacturing, accounting for rapid solidification, thermal cycling, segregation, defect formation, and process-specific constraints. Establish processing windows and heat-treatment strategies that enable reproducible material performance and translation from laboratory-scale alloy development toward manufacturing. Design and develop advanced structural alloys Use computational thermodynamics and materials modeling tools such as Thermo-Calc/CALPHAD to explore composition space, predict phase stability and transformations, and guide experimental alloy development.

Design alloys around application-specific combinations of mechanical performance, environmental resistance, temperature capability, manufacturability, and material availability. Plan and execute experimental campaigns to validate computational predictions and iteratively refine alloy compositions and processing conditions. Establish processing–structure–property relationships to guide material development Develop characterization strategies using techniques such as SEM/EDS, EBSD, XRD, optical microscopy, and mechanical testing to understand alloy behavior.

Connect composition and processing history to phase evolution, microstructure, defects, and resulting material performance. Use experimental results to identify mechanisms, refine alloy and process designs, and guide subsequent material development. Qualifications You meet our minimum qualifications if you… Have an MS in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline.

3+ years of relevant experience in physical metallurgy, alloy development, or advanced manufacturing. Have demonstrated experience in alloy design, processing, heat treatment, and processing–structure–property relationships in metallic materials. Have experience using Thermo-Calc, CALPHAD, or related computational materials tools to guide alloy or process development. Have hands-on experience with metallurgical processing and characterization, including relevant microscopy, diffraction, and mechanical testing techniques.

Are able to independently define technical approaches, interpret experimental results, and work effectively within multidisciplinary research teams. Hold an active Secret security clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship. You’ll go above and beyond if you… Have a PhD in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline with research focused on alloy design, physical metallurgy, or advanced manufacturing.

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