Senior Engineer; Metal Making

Recruitment Resourcer @ Ellaway Blues Consulting

We are seeking a Senior Engineer to join a leading industrial organization in Dallas, TX, supporting the growth of domestic manufacturing capabilities. Our client is pioneering advanced materials innovation across clean tech, defense, electrification, robotics, and aerospace. With a fully integrated supply chain and significant investment in next‑generation manufacturing, they are driving the resurgence of strategic sectors essential to automation, mobility, and energy systems.

Reporting directly to senior technical leadership, the Senior Engineer will lead the development and optimization of advanced material and alloy production processes. This role requires designing and executing experiments, leveraging simulation tools, and applying advanced characterization techniques to enhance process performance. The ideal candidate thrives in fast‑paced industrial environments, balancing practical execution with technical rigor, and actively contributes to innovation across metallurgical and electrochemical systems.

• Lead the development and optimization of advanced material and alloy production processes, with a focus on molten salt electrolysis and metallothermic reduction.
• Design and execute experiments to evaluate high‑temperature reaction kinetics, molten salt behavior, and reduction mechanisms.
• Apply simulation tools such as thermodynamic, transport, and electrochemical models to support process development.
• Characterize materials using XRD, XRF, LECO, SEM, and related techniques to validate and improve process performance.
• Utilize electrochemical instrumentation and techniques, including cyclic voltammetry and impedance spectroscopy, to refine and evaluate processes.

The ideal candidate holds a Ph.D. in Materials Science, Metallurgy, Chemical Engineering, Electrochemistry, or a related discipline and brings at least three years of hands‑on experience in molten salt electrolysis and/or metallothermic reduction. Deep technical knowledge of transport phenomena, thermodynamics, kinetics, and electrochemical analysis is essential. Experience with furnace reactors, custom electrolysis cells, and experimental setups in pyrometallurgical or electrometallurgical research is highly valued.

Not Applicable

Full‑time

Science and Engineering