Senior Engineer - Forging and Metallurgy

Job Description SummaryWe are seeking a highly experienced engineer with deep expertise in forging processes, metallurgy, heat treatment, materials characterization, and failure analysis to serve as the technical leader for forging process development and product characterization within our powder metallurgy manufacturing operation.
This individual will be the site's primary subject matter expert for forging and metallurgical evaluation, leading initiatives to optimize material properties, improve product performance, increase manufacturing capability, and support the development of new products and processes. The role requires close collaboration across manufacturing engineering, operations, quality, materials engineering, and product development teams to ensure robust, scalable, and capable manufacturing processes.

Job Description

Essential Responsibilities

Technical Leadership & Process Development

• Serve as the site's technical authority for forging process development, optimization, troubleshooting, and continuous improvement.
• Develop and refine forging and heat treatment processes to achieve required mechanical, structural, and metallurgical properties.
• Lead process characterization activities, including Design of Experiments (DOE), process window development, capability studies, and validation efforts.
• Establish technical strategies to improve process capability, material performance, product quality, manufacturing efficiency, and yield.
• Support capital projects, equipment upgrades, and implementation of new manufacturing technologies.

Metallurgy, Materials Engineering & Failure Analysis

• Investigate the relationships between material composition, processing conditions, microstructure, and product performance.
• Evaluate microstructure, grain flow, recrystallization behavior, and material properties resulting from forging and thermal processing.
• Lead root cause investigations of metallurgical defects, process deviations, nonconforming material, and field performance issues.
• Perform and direct failure analysis activities to identify mechanisms, corrective actions, and long-term process improvements.
• Establish metallurgical best practices, technical standards, and process controls.

Product Characterization & Testing

• Direct mechanical and metallurgical testing programs, including:
  • Tensile testing
  • Hardness testing
  • Fatigue testing
  • Fracture analysis
  • Microstructural evaluation
  • Failure analysis
  • Destructive and non-destructive testing methods
• Develop qualification and validation plans for new materials, products, and process changes.
• Analyze and interpret test results and provide recommendations to improve product performance, reliability, and manufacturability.

Continuous Improvement & Collaboration

• Lead structured problem-solving initiatives utilizing Lean, Six Sigma, statistical methods, and engineering fundamentals.
• Partner with product engineering teams to support new product introduction, design improvements, and manufacturing readiness.
• Collaborate with quality organizations to ensure compliance with internal, regulatory, and customer requirements.
• Mentor engineers and technical personnel in forging technology, metallurgy, materials characterization, and problem-solving methodologies.
• Represent the organization as the technical expert during customer, supplier, and regulatory interactions.
  

Required Qualifications

• Bachelor's degree in Metallurgical Engineering, Materials Science Engineering, Mechanical Engineering, or a related technical discipline.
• Minimum 10 years of experience in forging, metallurgical process development, materials engineering, or advanced manufacturing.
• Demonstrated expertise in forging process development, optimization, and troubleshooting.
• Strong knowledge of powder metallurgy, heat treatment, microstructure-property relationships, and materials characterization.
• Experience conducting and interpreting metallurgical and mechanical testing.
• Proven ability to solve complex manufacturing and materials-related challenges.
• Experience leading cross-functional technical projects from concept through implementation.

Preferred Qualifications

• Master's degree or PhD in Materials Science, Metallurgical Engineering, or a related discipline.
• 15+ years of forging and metallurgical process development experience.
• Experience with refractory metals, tungsten-based materials, high-temperature alloys, or powder metallurgy manufacturing.
• Extensive background in failure analysis and advanced materials characterization.
• Experience with DOE, statistical analysis, and process capability methodologies.
• Knowledge of advanced characterization methods such as SEM, EDS, EBSD, XRD, or similar analytical techniques.
• Lean Six Sigma Green Belt or Black Belt certification.

Desired Characteristics

• Recognized technical expert in forging and metallurgical processing.
• Strong analytical, scientific, and problem-solving capabilities.
• Ability to influence and lead across functions without direct authority.
• Excellent communication, mentoring, and technical presentation skills.
• Passion for continuous improvement and manufacturing excellence.
• Comfortable working in a hands-on production environment.

Impact of the Role

This position will provide technical leadership in forging technology, metallurgy, and materials engineering, driving advancements in product performance, process capability, manufacturing efficiency, and reliability. The successful candidate will play a key role in developing next-generation manufacturing processes and strengthening the organization's competitive advantage through world-class materials and process expertise.

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