Aerospace Thermal Spray Process Engineer

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

Benefits offered by this job

Health insurance

401(k) with employer matching

Paid time off

Bonuses

Parental leave

Job summary

Chromalloy is seeking an Aerospace Process Engineer - Thermal Spray Coating in Windsor, CT. You will develop and optimize coating processes, provide engineering support to manufacturing, and drive process improvements for gas turbine components.

You will work with robotics, masking procedures, grit blasting, and document control to ensure quality and reliability in aerospace components. The role emphasizes safety, collaboration, and continuous improvement.

Qualifications

• 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.

Responsibilities

• 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.

Skills

Root Cause Analysis

Lean Manufacturing

DMAIC

Statistical Problem Solving

Cross-functional Collaboration

Robotic Programming

Education

Bachelor’s degree in Engineering or related science

Tools

Siemens NX

Robotics/Automation Tools

Job description

Chromalloy is seeking an Aerospace Process Engineer - Thermal Spray Coating in Windsor, CT. You will develop and optimize coating processes, provide engineering support to manufacturing, and drive process improvements for gas turbine components.

You will work with robotics, masking procedures, grit blasting, and document control to ensure quality and reliability in aerospace components. The role emphasizes safety, collaboration, and continuous improvement.