Aluminum Metallurgist

ELLWOOD Group; Hubbard, Northern (OH, KY); On-site; USD 120,000 - 180,000; Full time

Job summary

Ellwood Aluminum LLC in Hubbard, OH is seeking an experienced Metallurgical Engineer to lead aluminum casting processes and defect analysis. You will mentor technicians, collaborate with design teams on new alloys, and ensure compliance with aerospace and industrial standards.

The role emphasizes technical leadership in metallurgy, process optimization, and supplier evaluation, with a strong focus on quality and safety in a high-performance foundry environment.

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science and Engineering, or related field is required
• MS/PhD with aluminum solidification/casting focus is highly preferred
• Minimum 10 years of hands-on metallurgical engineering in aluminum foundry/casting environment

Responsibilities

• Oversee and optimize melting, refining, alloying, and casting processes (high-pressure die casting, permanent mold, or sand casting)
• Serve as SME for aluminum metallurgy, microstructure evaluation, and heat treatment protocols
• Direct NDT and destructive testing programs to ensure product integrity and compliance with aerospace/automotive specs
• Lead RCFA for casting defects and implement corrective actions
• Partner with design teams to develop new aluminum alloys and evaluate casting tech to improve properties and reduce costs
• Mentor junior engineers, metallurgists, and lab technicians in foundry metallurgy
• Verify raw material suppliers and assist purchasing in supplier qualification and rating

Skills

Aluminum metallurgy

NDT testing

RCFA

Foundry operations

Materials testing

Technical writing

Cross-functional communication

Mentoring

Education

Bachelor of Science in Metallurgical Engineering

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

Tools

Optical microscopy

SEM/EDS

Hardness testing equipment

Job description

Ellwood Aluminum LLC
Hubbard, OH 44425, USA

Description

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.

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

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities This employer is required to notify all applicants of their rights pursuant to federal employment laws.For further information, please review the Know Your Rights notice from the Department of Labor.