Aluminum Metallurgist

Ellwood Aluminum LLC
Hubbard, OH 44425, USA

Essential Duties and Responsibilities:

• Process Optimization: Oversee and optimize aluminum melting, refining, alloying, and casting processes (including high-pressure die casting, permanent mold, or sand casting).
• Technical Leadership: Serve as the subject matter expert (SME) for aluminum metallurgy, microstructural evaluation, and heat treatment protocols.
• Quality & Compliance: Direct non-destructive testing (NDT) and destructive testing programs to guarantee product integrity and adherence to aerospace, automotive, or industrial specifications.
• Failure Analysis: Lead complex root-cause failure analysis (RCFA) for casting defects (e.g., porosity, inclusions, hot tears) and implement robust corrective actions.
• R&D and Innovation: Partner with product design teams to develop new aluminum alloys and evaluate emerging casting technologies to improve mechanical properties and reduce costs.
• Mentorship: Guide and mentor junior engineers, metallurgists, and laboratory technicians on best practices in foundry metallurgy.
• Verify raw material suppliers, including hardeners and scrap.
• Assist purchasing manager in identification of new suppliers and assist with ongoing rating of such suppliers.

Required Education and Experience

• Education: Bachelor of Science (B.S.) degree in Metallurgical Engineering, Materials Science and Engineering, or a closely related engineering discipline is required. A Master’s (M.S.) or Ph.D. with a research focus on aluminum solidification or casting is highly preferred.
• Experience: Minimum of 10 years of direct, hands‑on metallurgical engineering experience within an aluminum foundry or aluminum casting environment.

Certifications and Professional Alignments

• Professional Engineer (PE): Licensed Professional Engineer credential is highly preferred.
• ASQ
  
  Certifications:
  
  American Society for Quality (ASQ) Certified Quality Engineer (CQE) or Six Sigma Black Belt is highly desirable.
• NDT
  
  Certifications:
  
  Familiarity with ASNT Level II or III certifications (e.g., Liquid Penetrant, Ultrasonic, or Radiographic Testing) is a strong plus.
• Industry Memberships: Active participation in professional societies like the American Foundry Society (AFS) or ASM International is preferred.

Technical Skills, Training and Leadership

Qualifications:

• Deep understanding of aluminum phase diagrams, grain refinement, modification chemistry (e.g., Strontium, Titanium‑Boron), and degassing techniques.
• Proficiency with metallurgical laboratory equipment, including optical microscopy, Scanning Electron Microscopy (SEM/EDS), and hardness testers.
• Strong knowledge of international materials standards such as ASTM, AMS, SAE, and ISO.
• Exceptional analytical, problem‑solving, and technical writing skills.
• Ability to communicate effectively with Operations, Quality, Engineering, Sales, suppliers, and customers.
• Ability to interact directly with aerospace customer quality and engineering organizations.
• Strong technical writing and presentation skills.
• Ability to mentor, teach, train and transfer knowledge openly to those in positions where metallurgical specialties are part of career advancement.
• Mentor/Coach/Train:
  Quality Technicians and production personnel in metallurgy, defect identification, process control, and problem solving.

Safety

• Abides by all policies and procedures established by the Company including plant safety regulations and work rules
• Promotes a safety culture and ensures compliance with safety policies and rules,
• Safety improvement –Provides for continuous reduction of workplace hazards, risks, employee accidents.

Physical Demands

• The physical demands described here are representative of those that must be met by an employee to successfully perform the essential…