Senior Engineer - Forging and Metallurgy

Job Description Summary We 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…