Sr Engineer Materials - Steel Systems

Title:

Sr Engineer Materials – Aluminum Systems

Location:

Product Development Center (PDC), Wauwatosa, WI

Company:
Harley‑Davidson Motor Company

The Senior Materials Engineer will support the Product Development Process by providing deep technical expertise in aluminum materials, with a strong emphasis on cast aluminum components and systems. The role partners with product development, manufacturing, and suppliers to ensure robust material selection, processing, and performance. The engineer leads material‑related problem solving, including failure analysis and root‑cause investigations, focusing on improving aluminum casting quality and reliability for motorcycle applications.

• Apply applied knowledge of aluminum alloys, guiding material selection and design decisions for structural and cosmetic cast aluminum parts.
• Leverage expertise in high‑pressure die casting, permanent mold casting, and sand casting to improve casting quality, resolve defects, and support process development.
• Lead failure analysis and root‑cause investigations, performing metallurgical evaluations, interpreting lab results, and documenting findings with actionable recommendations.
• Apply knowledge of heat treatment and thermal processing specific to aluminum alloys, including corrosion behavior and surface treatments.
• Collaborate with design and validation teams to understand mechanical behavior, fatigue performance, and how it relates to casting quality, defects, and service loading conditions.
• Engage cross‑functionally, providing technical guidance to engineering teams, supporting supplier quality improvements, and ensuring alignment between design intent and manufacturing capability.

• Use standard metallurgical and analytical tools (optical emission spectroscopy, microscopy, fractography) to evaluate aluminum materials, interpreting results and linking them to component performance.

• Serve as a technical advisor in aluminum materials, mentoring others and communicating findings clearly to both technical and non‑technical stakeholders.

Bachelor’s Degree in Materials Engineering, Metallurgy, or a related field.

Minimum five years of materials engineering experience with hands‑on experience in aluminum materials and casting processes, preferably in product development or manufacturing environments.

Pay Range: $93,400 – $145,000

Travel Required:

0–10%

Visa Sponsorship:
Not eligible for visa sponsorship or transfer. Relocation:
Eligible for domestic relocation assistance.

Applicants must be authorized to work in the United States. Harley‑Davidson is an equal opportunity employer that continues to build a culture of inclusion, belonging, and equity through our commitment to attracting and retaining diverse talent from all backgrounds, without regard to race, color, religion, sex, sexual orientation, national origin, gender identity, age, disability, veteran status, or any other characteristic protected by law.