Failure Analysis Engineer - Materials & Reliability Expert

cai; Virginia (MN); On-site; USD 85,000 - 120,000; Full time

Job summary

CAI is seeking a Failure Analysis Engineer to join the Failure Analysis and Engineering team in Hampton, VA. This full-time on-site role focuses on investigating product failures, manufacturing issues, customer complaints, and field returns, applying materials engineering expertise and hands-on analysis.

The candidate will perform destructive and non-destructive analyses, generate detailed reports, and support root-cause investigations using structured methodologies.

Qualifications

• B.S. degree in materials/engineering or related field.
• 3–5 years of experience in failure analysis or related discipline.
• Hands-on root cause investigations and failure analysis activities.
• Knowledge of microscopy, SEM/EDS, X-ray, FTIR, DSC or related methods.
• Strong problem-solving and technical reporting skills.

Responsibilities

• Perform failure analysis on returns, defects, reliability issues and field failures.
• Conduct non-destructive and destructive analyses to identify failure modes.
• Generate clear technical reports documenting observations, conclusions, and recommendations.
• Support root cause investigations using 8D, 5 Why, Fishbone, and FTA methods.
• Collaborate with engineering, quality and manufacturing teams to resolve issues.
• Maintain records and ensure compliance with quality systems.

Skills

Failure analysis

Root cause investigations

Materials engineering

Engineering problem solving

Customer complaint investigations

Cross-functional collaboration

Education

B.S. degree in Materials/Mechanical/Electrical/Physics/Chemistry or related field

Tools

SEM/EDS

X-ray inspection

Microscopy

FTIR

DSC

Metallography

Job description

CAI is seeking a Failure Analysis Engineer to join the Failure Analysis and Engineering team in Hampton, VA. This full-time on-site role focuses on investigating product failures, manufacturing issues, customer complaints, and field returns, applying materials engineering expertise and hands-on analysis.

The candidate will perform destructive and non-destructive analyses, generate detailed reports, and support root-cause investigations using structured methodologies.