Lead Manufacturing Engineer â Coating Process Development
Lead Manufacturing Engineer â Coating Process Development
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$ 81700 - 136700
1 Vacancy
Job Description
Job Description Summary
Are you passionate about innovation Are you excited at the opportunity to electrify and decarbonize the worldWe operate with a founders mindset. We deliver innovation with passion speed and courage. We continuously challenge our thinking and are empowered to dream big and take smart risks.
What impact youll make
As a member of the Process Industrialization team you will be an active contributor to create maintain and execute the standard in how to develop and industrialize manufacturing processes using a team-based approach. This role sits within the Process Industrialization team and will execute new manufacturing process development. The focus will be on testing and developing new or improving upon existing manufacturing process by utilizing a standard framework.
If you know how to turn a thermal spray coating into a rock-solid quality repeatable production process we want you. Were seeking a hands-on Thermal Spray Development & Industrialization Engineer to lead the development qualification industrialization and sustainment focused on High Velocity Oxy-Fuel (HVOF) and Atmospheric Plasma Spray (APS) coating processes for gas turbine high-performance components.
This role blends practical coating cell work metallographic preparation microstructural analysis root-cause problem solving and the design of fixtures/masking to enable repeatable cost-effective production all while operating within our SQDC (Safety Quality Delivery Cost) values. You will work in a multi-disciplinary multi-group environment aligning R&D manufacturing quality and customer teams toward a common goal requiring clear concise communication and strong collaboration skills.
Job Description
What youll do
- Drive process development in GVL site converting a lab-proven parameters into stable and documented production processes. Develop and qualify HVOF and APS coating processes. The process transfer must be performed with a focus to the Frozen Process standards to the thermal spray critical parameters and at the same time understanding the process levels of freedom to optimize the process meets the print and specification requirements.
- Coating process development includes a large scope of operations such as masking grit blasting qualify inspections post coating final surface finish and heat treatments for bond coat and topcoat.
- Capability to operate thermal spray cells solid understanding of thermal spray parameters and their influence on the coating process sustainability. Validate robot programs and support robotic programming. Identify potential ways to optimize the coating program to improve the cycle time or eliminate coating defects.
- Thorough understanding of coating cell components and their interactions is required. The candidate should be capable of diagnosing equipment or process issues and executing corrective and preventive actions to ensure long-term process stability.
- In-depth expertise in microstructure evaluation and mechanical testing (hardness and tensile strength) is essential. The candidate must be able to perform root cause analysis of coating defects (e.g. metallic and TBC ceramic coatings porosity DVC spacing lamellar structure poor adhesion oxidation pull-outs unmets) based on microstructural evidence requiring a comprehensive understanding of how thermal spray process parameters affect coating microstructure.
- Hands-on experience in a metallographic lab including knowledge of the purpose and operation of standard laboratory equipment used in sample preparation and analysis. Perform optical metallography porosity DVC microstructural features microhardness testing to assess coating quality.
- Develop and optimize tooling and masking to ensure repeatability standoff control and overspray containment. Translate CAD concepts into tested production-ready tooling solutions.
- Responsible for process industrialization and scale-up activities based on 10-steps standard including creation of control plans process gap identification detailed work instructions and comprehensive operator training materials. Support implementation of SPC and lead NPI transfers ensuring readiness for full-scale production and compliance with internal and external audits.
- Partner with the process qualification team to determine coating process readiness by analyzing Cp and Cpk metrics. Use insights from eCAV data to identify improvement opportunities and implement changes to enhance first-pass yield (FPY). Lean Manufacturing & Process Flow.
- Leverage Lean manufacturing concepts such as takt time value stream optimization and waste reduction to enhance operational efficiency. Work cross-functionally to implement workflows that improve throughput without compromising safety or product quality.
- Collaborate across R&D engineering QA operations suppliers and customers to ensure alignment on project goals and timelines.
- Present complex data and insights in a clear concise manner tailored to technical and non-technical stakeholders.
What youll bring (Basic Qualifications)
- Bachelors degree in Materials Science Metallurgical Engineering Mechanical Engineering or related field (advanced degree preferred).
- 4 years of hands-on thermal spray process development experience (HVOF & APS).
- Strong skills in coating microstructure evaluation and metallographic analysis (optical image analysis).
- Excellent written and verbal communication skills; proven track record working in multi-group environments toward shared goals.
- Ability and desire to work on site in a manufacturing environment
- Ability to work off-shift or flexible schedule at times as required by project timelines
- This role is restricted to U.S. persons (i.e. U.S. citizens permanent residents and other protected individuals under the Immigration and Naturalization Act 8 U.S.C. 1324b(a)(3)) due to access to export-controlled technology. GE will require proof of status prior to employment
What will make you stand out
- Proven experience designing fixtures/masking for production coating applications (SolidWorks NX or equivalent CAD).
- Background in process documentation control plans FMEA and structured problem-solving (e.g. fishbone 5Y 8D).
- Experience with MCrAlY bondcoats ceramic topcoats (e.g. YSZ) coatings.
- Gas turbine or aerospace coatings qualification experience.
- Knowledge of blasting masking heat treatment and post-processing of coated parts.
- Familiarity with nondestructive inspection (NDT) for coatings.
- Lean/Six Sigma certification or equivalent continuous improvement experience.
Pay Transparency
For U.S. based candidates only for purposes of complying with U.S. pay transparency requirements the base pay range for this position is $81700.00 - $136700.00 USD Annual. The specific pay offered may be influenced by a variety offactors including the candidates experience education and skill set. This position is also eligible for a10% performance bonus/variable incentive compensation/equity. This posting is expected to close on or after September 5 2025.
*The Company pays a geographic differential of 110% 120% or 130% of salary in certain areas.
Healthcare benefits include medical dental vision and prescription drug coverage; access to a Health Coach a 24/7 nurse-based resource; and access to the Employee Assistance Program providing 24/7 confidential assessment counseling and referral services. Retirement benefits include the GE Retirement Savings Plan a tax-advantaged 401(k) savings opportunity with company matching contributions and company retirement contributions as well as access to Fidelity resources and planning consultants. Other benefits include tuition assistance adoption assistance paid parental leave disability insurance life insurance and paid time-off for vacation or illness.
General Electric Company Ropcor Inc. their successors and in some cases their affiliates each sponsor certain employee benefit plans or programs (i.e. is a Sponsor). Each Sponsor reserves the right to terminate amend suspend replace or modify its benefit plans and programs at any time and for any reason in its sole discretion. No individual has a vested right to any benefit under a Sponsors welfare benefit plan or program. This document does not create a contract of employment with any individual.
Benefits Available to You
GE employees rise to the challenge of building a world that order to meet this mission we provide varied competitive benefits to help support our workforce: Our Culture GE Vernova ()
- Our compensation & benefits are designed to help you manage your personal and family needs while rewarding high performers. We offer a robust benefits package depending on your employment status and your national requirements.
- A healthy balanced lifestyle can mean different things to different people. Weve created programs that support the way you live and work today.
- GE invests to provide opportunities to grow your career by providing a path for continued on-the-job learning and development.
Inclusion & Diversity
At GE we believe in the value of your unique identity background and experiences. We are committed to fostering an inclusive culture where everyone feels empowered to do their best work because they feel accepted respected and that they belong. Click here to learn more: GE Gas Power
GE Gas Power engineers cleaner more accessible energy that people depend on powering growth and prosperity for people everywhere. Our leading technologies produce a third of the worlds electricity thanks to our talented people who make gas work for our customers stakeholders and the world. Through relentless innovation and continuous partnership with our customers we are building the energy technologies of the future and providing the cleaner more efficient power people depend on today.
This role requires access to U.S. export-controlled information. If applicable final offers will be contingent on ability to obtain authorization for access to U.S. export-controlled information from the U.S. Government.
Additional Information
GE Vernova offers a great work environment professional development challenging careers and competitive compensation. GE Vernova is anEqual Opportunity Employer. Employment decisions are made without regard to race color religion national or ethnic origin sex sexual orientation gender identity or expression age disability protected veteran status or other characteristics protected by law.
GE Vernova will only employ those who are legally authorized to work in the United States for this opening. Any offer of employment is conditioned upon the successful completion of a drug screen (as applicable).
Relocation Assistance Provided: Yes
Employment Type
Full-Time
