Senior Materials Engineer (Metals, Forming & Castings)

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.

Advise Design Manufacturing and Quality teams on metal selection process capability and process-induced failure modes for forming stamping and casting operations (DFMEA/PFMEA).

Draft and maintain material and process specifications quality acceptance criteria and ASTM/ISO/SAE test procedures.

Support supplier material and process qualification for formed stamped and cast metal components including review of PPAP submissions and material certifications.

Manage lab test plans equipment calibration SOPs and safety standards while directing external vendor labs and mentoring junior engineers.

Bachelors or Masters degree in Materials Science & Engineering Metallurgical Engineering Mechanical Engineering or a related field.

8 years of experience in materials engineering failure analysis or metallurgical engineering ideally in automotive aerospace or heavy equipment.

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.

Strong experience with mechanical testing (Instron/UTM systems) and failure analysis techniques (fractography SEM/EDS metallography hardness testing).

Demonstrated track record independently leading root cause investigations and driving corrective actions to closure with cross-functional teams.

Working knowledge of ASTM/ISO/SAE test standards and experience developing test specifications.

Excellent written and verbal communication skills with the ability to translate technical findings for non-materials audiences and leadership.

Experience mentoring or directing the work of junior engineers or technicians.

Experience with polymers composites adhesives/bonded joints or coatings failure analysis.

Familiarity with forming/stamping simulation tools (e.g. AutoForm LS-DYNA) casting simulation or DFMEA/PFMEA processes.

Experience with supplier quality engineering PPAP or material certification review.

Prior experience in high-volume automotive manufacturing or a vehicle development environment.

Advanced degree (MS/PhD) in Materials Science or Metallurgy.