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, ensuring compliance with Frozen Process standards and thermal spray critical parameters.
• Lead coating process development across masking, grit blasting, shot peen, and final surface finish treatment.
• Qualify inspections, post-coating final surface finish, and heat treatments for bond coat and topcoat.
• Operate robotic thermal spray cells, validate robot programs, support robotic programming, and PLC I/O logic.
• Identify opportunities to optimize coating programs to improve cycle time or eliminate coating defects.
• Diagnose equipment or process issues, execute corrective actions, and ensure long-term process stability.
• Perform microstructure evaluation, mechanical testing, and root-cause analysis of coating defects such as contamination, poor adhesion, oxidation, cracking, and voids.
• Operate metallographic lab, conduct optical metallography, porosity, microstructural features, and microhardness testing.
• Develop and optimize tooling and masking to ensure repeatability, standoff control, and overspray containment.
• Translate CAD concepts into production-ready tooling solutions.
• Support process industrialization and scale-up activities: create control plans, identify process gaps, develop detailed work instructions, and produce operator training materials.
• Implement SPC and lead NPI transfers, ensuring readiness for full-scale production and compliance with audits.
• Partner with the process qualification team to determine coating process readiness via Cp and Cpk metrics and eCAV data insights to enhance FPY.
• Apply Lean manufacturing concepts to improve operational efficiency, takt time, value stream, and waste reduction.
• Collaborate across R&D, engineering, QA, operations, suppliers, and customers to align project goals and timelines.
• Present complex data and insights clearly to both 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.

• Strong skills in coating microstructure evaluation and metallographic analysis.
• Excellent written and verbal communication skills; proven track record working in multi-group environments.
• Ability to work on site in a manufacturing environment and on flexible schedule.
• Experience designing fixtures/masking for production coating applications using CAD (NX or equivalent).
• Background in process documentation, control plans, FMEA, and structured problem-solving (fishbone, 5Y, 8D).
• Experience with gas turbine or aerospace coatings, blasting, masking, heat treatment, and post-processing of coated parts.
• Familiarity with nondestructive inspection for coatings.
• Lean/Six Sigma certification or equivalent continuous improvement experience.
• Strong oral and written communication skills and documented ability to resolve problems.
• Ability to document, plan, market, and execute programs; established project management skills.

• Relocation assistance available.
• Pay range: $81,700 - $136,700 (salary may vary by experience, location, and geographic differential).
• Bonus eligibility: ineligible.
• Medical, dental, vision, and prescription drug coverage;
  Health Coach; 24/7 nurse-based resource.
• Employee Assistance Program with confidential counseling and referrals.
• Retirement benefits: GE Vernova Retirement Savings Plan (401(k) with company match and contributions).
• Tuition assistance, adoption assistance, paid parental leave, disability benefits, and life insurance.
• 12 paid holidays and permissive time off.

GE Vernova is an Equal 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).