Aluminum Metallurgist

Ellwood; Hubbard (OH); On-site; USD 110,000 - 160,000; Full time

Job summary

Ellwood Aluminum in Ohio is seeking a senior Metallurgist to lead and optimize aluminum melting, refining, alloying and casting operations across a range of processes including high-pressure die casting and sand casting.

The role requires a BS in Metallurgical Engineering with 10+ years in aluminum foundries; MS/PhD preferred. You will serve as SME for metallurgy, oversee NDT/destructive testing, RCFA, and mentor engineers and technicians while engaging with suppliers and design teams.

Qualifications

• BS in Metallurgical Engineering required; MS/PhD preferred for aluminum solidification/casting.
• 10 years direct, hands-on metallurgical experience in an aluminum foundry or casting environment.
• PE license preferred; ASQ CQE or Six Sigma Black Belt desirable.

Responsibilities

• Oversee and optimize aluminum melting, refining, alloying and casting processes.
• Act as SME for aluminum metallurgy, microstructure, and heat treatment.
• Direct NDT and destructive testing programs for part integrity.
• Lead RCFA for casting defects and implement corrective actions.
• Partner with design teams to develop new alloys and evaluate casting tech.
• Mentor junior engineers and lab staff in foundry metallurgy.
• Verify raw material suppliers and assist with supplier rating.
• Support purchasing in identifying new suppliers.

Skills

Aluminum metallurgy

RCFA

Metallurgical testing

Technical writing

Mentorship

Supplier evaluation

Education

Bachelor of Science in Metallurgical Engineering

Master’s or Ph.D. in aluminum solidification / casting (preferred)

Tools

Optical microscopy

SEM/EDS

Hardness testing

Job description

• Process Optimization: Oversee and optimize aluminum melting, refining, alloying, and casting processes (including high-pressure die casting, permanent mold, or sand casting).


• Technical Leadership: Serve as the subject matter expert (SME) for aluminum metallurgy, microstructural evaluation, and heat treatment protocols.


• Quality & Compliance: Direct non-destructive testing (NDT) and destructive testing programs to guarantee product integrity and adherence to aerospace, automotive, or industrial specifications.


• Failure Analysis: Lead complex root-cause failure analysis (RCFA) for casting defects (e.g., porosity, inclusions, hot tears) and implement robust corrective actions.


• R&D and Innovation: Partner with product design teams to develop new aluminum alloys and evaluate emerging casting technologies to improve mechanical properties and reduce costs.


• Mentorship: Guide and mentor junior engineers, metallurgists, and laboratory technicians on best practices in foundry metallurgy.


• Verify raw material suppliers, including hardeners and scrap.


• Assist purchasing manager in identification of new suppliers and assist with ongoing rating of such suppliers.

Metallurgist Position Details:

Essential Duties and Responsibilities:

• Process Optimization: Oversee and optimize aluminum melting, refining, alloying, and casting processes (including high-pressure die casting, permanent mold, or sand casting).


• Technical Leadership: Serve as the subject matter expert (SME) for aluminum metallurgy, microstructural evaluation, and heat treatment protocols.


• Quality & Compliance: Direct non-destructive testing (NDT) and destructive testing programs to guarantee product integrity and adherence to aerospace, automotive, or industrial specifications.


• Failure Analysis: Lead complex root-cause failure analysis (RCFA) for casting defects (e.g., porosity, inclusions, hot tears) and implement robust corrective actions.


• R&D and Innovation: Partner with product design teams to develop new aluminum alloys and evaluate emerging casting technologies to improve mechanical properties and reduce costs.


• Mentorship: Guide and mentor junior engineers, metallurgists, and laboratory technicians on best practices in foundry metallurgy.


• Verify raw material suppliers, including hardeners and scrap.


• Assist purchasing manager in identification of new suppliers and assist with ongoing rating of such suppliers.

Required Education And Experience

• Education: Bachelor of Science (B.S.) degree in Metallurgical Engineering, Materials Science and Engineering, or a closely related engineering discipline is required. A Master’s (M.S.) or Ph.D. with a research focus on aluminum solidification or casting is highly preferred.


• Experience: Minimum of 10 years of direct, hands-on metallurgical engineering experience within an aluminum foundry or aluminum casting environment.

Certifications and Professional Alignments

• Professional Engineer (PE): Licensed Professional Engineer credential is highly preferred.


• ASQ Certifications: American Society for Quality (ASQ) Certified Quality Engineer (CQE) or Six Sigma Black Belt is highly desirable.


• NDT Certifications: Familiarity with ASNT Level II or III certifications (e.g., Liquid Penetrant, Ultrasonic, or Radiographic Testing) is a strong plus.


• Industry Memberships: Active participation in professional societies like the American Foundry Society (AFS) or ASM International is preferred.


• Certified Level II UT inspection per NAS 410.

Technical Skills, Training and Leadership Qualifications:

• Deep understanding of aluminum phase diagrams, grain refinement, modification chemistry (e.g., Strontium, Titanium-Boron), and degassing techniques.


• Proficiency with metallurgical laboratory equipment, including optical microscopy, Scanning Electron Microscopy (SEM/EDS), and hardness testers.


• Strong knowledge of international materials standards such as ASTM, AMS, SAE, and ISO.


• Exceptional analytical, problem-solving, and technical writing skills.


• Ability to communicate effectively with Operations, Quality, Engineering, Sales, suppliers, and customers.


• Ability to interact directly with aerospace customer quality and engineering organizations.


• Strong technical writing and presentation skills.


• Ability to mentor, teach, train and transfer knowledge openly to those in positions where metallurgical specialties are part of career advancement.


• Mentor/Coach/Train: Quality Technicians and production personnel in metallurgy, defect identification, process control, and problem solving.

Safety

• Abides by all policies and procedures established by the Company including plant safety regulations and work rules


• Promotes a safety culture and ensures compliance with safety policies and rules,


• Safety improvement - Provides for continuous reduction of workplace hazards, risks, employee accidents.

Physical Demands

• The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals to perform the essential functions of the job.


• The employee may occasionally move up to Specific vision abilities required by this job include close vision and ability to adjust focus. While performing the duties of this job, the employee is regularly required to stand, walk, move throughout the plant, and operate hand and/or mobile equipment, talk and hear. The employee is occasionally required to reach with hands and arms and climb, stoop, kneel, or crouch. The work environment has exposure to both inside and outside environmental conditions including temperature changes and may at times be exposed to heat or cold for periods of more than one hour.

Ellwood Aluminum is an EEO Employer