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.

• 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.

• 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.

• 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.

• 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.

• 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 treatment, microstructure-property relationships, and materials characterization.
• Experience conducting and interpreting metallurgical and mechanical testing.
• Proven ability to solve complex manufacturing and materials-related challenges.
• Experience leading cross-functional technical projects from concept through implementation.

• Master's degree or PhD in Materials Science, Metallurgical Engineering, or a related discipline.
• 15+ years of forging and metallurgical process development experience.
• Experience with refractory metals, tungsten-based materials, high-temperature alloys, or powder metallurgy manufacturing.
• Extensive background in failure analysis and advanced materials characterization.
• Experience with DOE, statistical analysis, and process capability…