Senior Materials & Process Engineer - Powder Metallurgy

The role

You will serve as the technical lead for the end-to-end powder metallurgy manufacturing process. You will optimize production lines, scale new NdFeB magnet formulations, and troubleshoot materials anomalies.

What you will do

• Own and optimize the powder metallurgy pipeline including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments
• Correlate process variables to magnetic properties, microstructure, and part quality
• Lead root-cause failure analyses for sample defects and implement corrective actions
• Transition new alloy compositions from pilot scale to robust, high-volume production
• Define technical specifications
• Partner with Manufacturing team for selection and commissioning of next-generation manufacturing equipment

Required qualifications

• Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline
• 8+ years of hands-on engineering experience in powder metallurgy processing
• Experience with reactive metal powder processing, protective inert atmospheres, vacuum thermal processing, and advanced sintering kinetics
• Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC
• Strong experience in design of experiments, statistical processing, and leading research efforts
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities
• Ability to climb stairs, stand and walk for extended periods
• Ability to work in environments that may be hot, humid, or noisy
• Ability to use personal protective equipment, including respirators

Nice to have

• Direct experience in the manufacturing of sintered NdFeB permanent magnets and grain boundary diffusion processes
• Strong proficiency in evaluating magnetic materials properties and interpreting microstructural data
• Experience utilizing data analysis tools (such as Python, MATLAB, or JMP) to analyze manufacturing quality datasets or automate performance mapping
• Familiarity with ISO 9001 or IATF 16949 quality management standards
• Industrial manufacturing setting

Before you apply

• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities

About the company

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. They serve critical industries such as defense, aerospace, and automotive.