Senior Reliability Engineer

Frore Systems is an industry leader in advanced thermal technologies, driving enhanced performance across data centers, embedded industrial systems, and consumer electronics. The company is renowned for its innovative solutions, including Liquid Jet™, a breakthrough cooling technology that significantly increases GPU performance and Air Jet®, the world's first solid-state active cooling chip for diverse commercial and edge-AI devices. Frore Systems is headquartered in Silicon Valley with manufacturing operations based in Taiwan.

Role Overview

The Metal Corrosion and Erosion Scientist for Liquid Cooling Systems specializes in understanding, predicting, and mitigating material degradation in liquid-cooled environments. This role focuses on corrosion, erosion, and erosion–corrosion mechanisms driven by coolant chemistry, flow conditions, temperature gradients, and mixed-material assemblies. The position supports the development of reliable, long-life liquid cooling solutions for high-performance thermal management applications.

Key Responsibilities

Corrosion & Erosion Mechanisms in Liquid Cooling

• Investigate corrosion and erosion behavior of metals and alloys in liquid cooling environments, including water, water-glycol mixtures, dielectric fluids, and specialty coolants.
• Study uniform corrosion, pitting, crevice corrosion, galvanic corrosion, flow-accelerated corrosion, and erosion–corrosion under controlled flow conditions.
• Evaluate the effects of coolant chemistry (pH, conductivity, dissolved oxygen, inhibitors, contaminants) on material degradation.
• Assess corrosion risks associated with mixed-metal systems (e.g., aluminum–copper–stainless steel interfaces).
• Design and execute laboratory corrosion and erosion testing using flow loops, cold plate test rigs, and immersion systems.
• Perform electrochemical testing including potentiodynamic polarization, EIS, LPR, and galvanic coupling measurements in relevant coolants.
• Conduct erosion and erosion–corrosion testing under representative flow velocities, Reynolds numbers, and particle loading (if applicable).
• Simulate thermal cycling, stagnation, and startup/shutdown conditions typical of liquid cooling systems.
• Characterize corrosion products, surface damage, and wear features using optical microscopy, SEM/EDS, XRD, and profilometry.
• Analyze microstructural effects of corrosion on base metals, brazed joints, welds, and additively manufactured components.
• Evaluate surface roughness evolution and its impact on thermal and hydraulic performance.
• Assess coating integrity and degradation mechanisms in liquid environments.

Failure Analysis & Reliability

• Perform root cause failure analysis of liquid-cooled components such as cold plates, manifolds, heat exchangers, tubing, and fittings.
• Identify failure modes related to corrosion, erosion, leakage, clogging, and flow restriction.
• Correlate field failures with laboratory data to validate test methods and models.
• Recommend corrective actions to prevent recurrence and improve system reliability.
• Develop corrosion mitigation strategies including material selection, surface treatments, coatings, corrosion inhibitors, and coolant specification control.
• Evaluate compatibility of metals, polymers, elastomers, and coatings in liquid cooling assemblies.
• Support design teams with materials guidance to reduce galvanic couples and erosion-prone geometries.
• Contribute to design-for-reliability and lifetime prediction models for liquid cooling systems.

Standards, Quality & Cross-Functional Support

• Apply relevant standards and best practices (ASTM, AMPP/NACE, ISO, industry cooling specifications).
• Support qualification, validation, and reliability testing for new cooling designs.
• Collaborate with thermal, mechanical, manufacturing, and quality engineers.
• Interface with coolant suppliers, coating vendors, and external testing laboratories.

Documentation & Communication

• Prepare detailed test plans, technical reports, and design guidelines.
• Present findings to engineering leadership and program teams.
• Support internal training on corrosion risks and mitigation in liquid cooling systems.
• Maintain traceable experimental data and failure analysis…