Senior Metallurgical Engineer - Failure Analysis & Materials Reliability

As a Senior Metallurgical Engineer - Failure Analysis & Materials Reliability, in our Energy Research & Innovation organization, you’ll help solve complex materials reliability challenges to support the safe, reliable performance of our refining, midstream, and renewable fuel assets. This is an opportunity to apply advanced scientific expertise, shape better methods and tools, and turn insights into practical value across the enterprise.

• Lead complex materials failure investigations and root-cause analyses, using metallography, fractography, and advanced materials characterization to identify failure mechanisms and recommend solutions.
• Plan and manage a portfolio of research and technical support projects, balancing priorities, resources, schedules, technical risk, and the needs of multiple sites and customers.
• Design and conduct experiments, testing, data collection, and analysis using appropriate research methods to evaluate technical problems and translate results into practical applications.
• Apply advanced diagnostic methods, laboratory techniques, scientific software, simulation tools, and company-approved AI tools to investigate welding, corrosion, metallurgy, and other materials reliability challenges.
• Identify gaps in existing procedures, methodologies, and tools; develop improved test methods, diagnostic capabilities, and reusable standards that strengthen the quality and efficiency of technical support.
• Analyze laboratory, field, process, and other data to assess business impacts, prepare clear reports, and develop business cases that support investments in proactive investigations and research.
• Provide specialist advice on technical findings, standards, procedures, and emerging materials reliability issues, enabling sites and stakeholders to make informed decisions.
• Serve as a subject matter expert in materials science, metallurgy, welding, and corrosion damage mechanisms; mentor colleagues, review technical work, and provide guidance to less experienced scientists and engineers.
• Monitor external developments, regulations, and industry practices; contribute to technical publications and knowledge sharing, represent Phillips 66 in technical forums, and promote safe laboratory and operating practices.

• Legally authorized to work in the job posting country
• Bachelor’s degree or equivalent level in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering or a related scientific or engineering field
• 6 or more years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis
• 3 or more years of hands‑on experience supporting refining, midstream, or renewable fuel assets
• Travel up to 5% of the time
• Work around chemicals, including acids and bases

• 10 or more years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis
• 8 or more years of hands‑on experience supporting refining, midstream, or renewable fuel assets
• Strong working knowledge of corrosion mechanisms, materials degradation, welding and metallurgy, chemical treatment, coatings, fouling mitigation, or corrosion modeling
• Experience conducting or supporting failure analysis, root‑cause investigations, risk assessments, or laboratory corrosion studies
• Experience with corrosion modeling or simulation tools such as COMSOL, Aspen HYSYS, OLI, or similar applications
• Proficiency selecting, interpreting, and…