Lead Surface Preparation​/Metallurgy Specialist

Job Description Summary

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.

• Drive process development onsite, converting a ‘lab‑proven’ parameters into stable and documented production processes.
• Develop and qualify HVOF and Plasma 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, shot peen, final surface finish treatment.
• Qualify inspections, post coating final surface finish, and heat treatments for bond coat and topcoat.
• Capability to operate robotic thermal spray cells, solid understanding of thermal spray parameters and their influence on the coating process sustainability.
• Validate robot programs, support robotic programming, and PLC I/O logic.
• 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., contamination, poor adhesion, oxidation, cracking and voids) 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 Built in Quality, 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.

• Bachelor’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, or related field.
• Minimum of 3 years of hands‑on thermal spray process development experience (thermal coatings).

• Strong skills in coating microstructure evaluation and…