Aerospace Thermal Spray Process Engineer

Chromalloy; Windsor (CT); On-site; USD 95,000 - 130,000; Full time

Job summary

Chromalloy in Windsor, CT is seeking a Thermal Spray Process Engineer to support the repair and overhaul of gas turbine components. You will develop, optimize, and sustain coating processes for aerospace parts, including surface preparation, masking, and robotic spray applications.

The role emphasizes process control, quality, delivery, and safety, with collaboration across production, maintenance, and quality teams to drive continuous improvement and operational excellence.

Qualifications

• Bachelor’s degree in Engineering or related science 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.

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.

Skills

Thermal spray coating

Robotic programming

Process optimization

Kaizen / Lean

Six Sigma

Education

Bachelor’s degree in Engineering

Tools

Siemens NX

3D CAD

Job description

Chromalloy in Windsor, CT is seeking a Thermal Spray Process Engineer to support the repair and overhaul of gas turbine components. You will develop, optimize, and sustain coating processes for aerospace parts, including surface preparation, masking, and robotic spray applications.

The role emphasizes process control, quality, delivery, and safety, with collaboration across production, maintenance, and quality teams to drive continuous improvement and operational excellence.