Aerospace Process Engineer - Thermal Spray Coating

Chromalloy Corporation; Windsor (CT); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Comprehensive benefits starting day 1

Development & progression programs

Paid time off, holidays, parental/leav

Competitive pay with bonuses

Job summary

Chromalloy is seeking a Thermal Spray Process Engineer to support repair and overhaul of critical gas turbine components. You will develop, optimize, and sustain manufacturing processes for surface prep, masking, thermal spray coating, robotic programming, and process control.

You will impact product quality, turnaround time and operational efficiency while helping ensure aviation safety worldwide. Location: Windsor, CT; Travel: occasional; Schedule: On-site.

Qualifications

• Bachelor’s degree in Engineering or related science‑based discipline.
• 3+ years of engineering experience in a manufacturing environment; aerospace preferred.
• Experience with manufacturing operations, process development and continuous improvement.

Responsibilities

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.
• Provide day‑to‑day engineering support to production operations, monitor yield, and improve process capability.
• Perform root cause analysis and corrective actions to resolve issues and prevent recurrence.
• Lead activities ensuring production readiness of thermal spray equipment and related technologies.
• Design and implement tooling, fixtures, gauging, and process improvements for safety, quality and productivity.
• Program and optimize 6‑axis robotic systems used in thermal spray coating applications.
• Develop spray parameters for new coating materials and improve existing processes.
• Create process documentation including SOPs, specs, calibration, training, and quality records.

Skills

Root cause analysis

Lean Manufacturing

Six Sigma

DMAIC

Kaizen

Robotic programming

Education

Bachelor's degree in Engineering or related science

Tools

Siemens NX

Job description

Chromalloy is a global engineering & solutions company. We are a leading provider of aftermarket parts, repairs, and solutions that safely & reliably extend the life of aircraft engines and gas turbines. We develop, manufacture and repair critical turbine components for a range of engine platforms. Our solutions support the engines running the aerospace, energy and defense industries around the world.

Video: What We Do

Why work at Chromalloy?

Chromalloy employees are proud, passionate problem-solvers who strive to live our values every day. A career with Chromalloy is an opportunity to learn from top industry experts, work with important technologies, and unlock a passion for innovation. Join our team of experts, innovators and problem-solvers delivering world‑class solutions for our customers. As a global company, we are committed to creating an inclusive environment where all employees feel represented, heard, and able to bring their best selves to work every day. Be part of something bigger with Chromalloy!
Our Total Rewards Program is designed to support you today and in the future.

• Comprehensive and flexible benefit options starting on day one, including medical, dental, vision, EAP, wellness incentives, and 401(k) with employer matching.
• Development & progression opportunities for every employee – regular performance conversations, training and development curriculum, and engineering fellowship programs.
• Paid time off, including vacation, sick time, paid holidays, and parental leave—all eligible on your first day of employment!
• Competitive pay, including eligibility for quarterly and annual bonuses, depending on role and site.
  

Eligibility for individual benefit plans may vary based on employment status.

Job Summary

We’re looking for a Thermal Spray Process Engineer to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to surface preparation, masking, thermal spray coating application, robotic programming, and process control. Your work will directly impact product quality, performance, turnaround time, delivery, and operational efficiency while helping ensure the reliability of components that support aviation safety worldwide.

Work That Matters

At Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.
Location: Windsor, CT
Travel: Occasional travel required
Schedule: On-site

What You’ll Be Doing

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.
• Provide day‑to‑day engineering support to production operations, including monitoring yield, reducing rework, and improving process capability.
• Perform root cause analysis and corrective actions to resolve process and quality issues and prevent recurrence.
• Lead activities that ensure production readiness of thermal spray equipment and associated process technologies.
• Design, develop, and implement tooling, fixtures, gauging, and process improvements that enhance safety, quality, and productivity.
• Program and optimize 6‑axis robotic systems used in thermal spray coating applications.
• Develop spray parameters for new coating materials and continuously improve existing coating processes.
• Develop and optimize masking and surface preparation methods, including grit blasting procedures.
• Create and maintain process documentation, including operating procedures, work instructions, process specifications, calibration instructions, training materials, and quality records.
• Support operator training and collaborate with maintenance teams to establish effective preventive maintenance programs.
• Participate in Kaizen, Lean Manufacturing, and continuous improvement initiatives to improve process performance, quality, delivery, and cost.
• Apply Six Sigma and DMAIC methodologies to solve complex manufacturing challenges and drive sustainable process improvements.
  

What We’re Looking For

• Bachelor’s degree in Engineering or a related science‑based discipline such as Materials Science, Chemistry, or Physics.
• 3+ years of engineering experience in a manufacturing environment; aerospace manufacturing, repair, overhaul, or gas turbine experience preferred.
• Experience supporting manufacturing operations, process development, and continuous improvement initiatives.
• Knowledge of root cause analysis, corrective action systems, and statistical problem‑solving methodologies.
• Familiarity with Lean Manufacturing principles and structured problem‑solving techniques.
• Strong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.
  

Nice to Have

• Experience with thermal spray equipment and coating process development.
• Experience programming and optimizing 6‑axis robotic systems.
• Working knowledge of 3D CAD software such as Siemens NX.
• Knowledge of thermal spray technologies, including:
• Atmospheric Plasma Spray (APS)
• Dual Wire Arc Spray
• Combustion Spray
• Experience with aerospace masking techniques and fixturing design.
• Knowledge of surface preparation requirements, including grit blasting processes.
• Experience supporting aerospace component repair, overhaul, or manufacturing operations.
• Lean Six Sigma Green Belt certification or participation in Kaizen events.
• Familiarity with aerospace quality systems and process control methodologies.
  

Work Environment & Physical Requirements

• Work is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.
• Regular interaction with production areas, laboratories, and repair operations is required.
• Ability to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.
• Ability to occasionally lift and carry up to 25 pounds.
• Must be able to wear required personal protective equipment (PPE) and comply with all safety policies and procedures.
  

This position may require work hours outside of the regularly scheduled hours to meet operational needs. This may include work during evenings, weekends, and/or holidays. Additional work hours are assigned based on business requirements. Non‑exempt employees will be paid overtime in accordance with applicable federal, state, and local laws.
The salary range for this position reflects a broad spectrum of experience levels. Individual compensation within the range is determined by multiple factors, including relevant experience, education, certifications, job related skills, internal equity, and market conditions. We evaluate each candidate individually to ensure fair and competitive pay decisions.
Due to government regulation only US persons (U.S. citizen, U.S. naturalized citizen, U.S. permanent resident, holder of U.S. approved political asylee or refugee status) may be considered for this role.
Chromalloy participates in E‑Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.
Any offer of employment will also be conditioned upon the successful completion of a background investigation and drug screen in accordance with company policy and applicable federal and state regulations.
Chromalloy is an equal opportunity employer - vets/disabled.
In the United States, if you need a reasonable accommodation for the online application process due to a disability, please contact: https://www.chromalloy.com/contact-us/