Failure Analysis Engineer/MTS

Covalent; Sunnyvale (CA); Hybrid; USD 90,000 - 140,000; Full time

Job summary

Covalent, a modern analytical services and engineering firm in Sunnyvale, CA, is seeking a hands-on MTS – Failure Analysis Engineer to join the FA team. You will investigate failures using analytical techniques, develop failure hypotheses, and communicate conclusions with customers.

The role emphasizes X-ray imaging, SEM/EDS, cross-sectioning, and thermal/electrical localization; you will grow to lead customer interactions and analysis strategies, while learning new FA techniques and maintaining

Qualifications

• BS, MS, or PhD in Materials Science, Electrical Engineering, Mechanical Engineering, Physics, Applied Physics, or a related technical discipline.
• Strong experimental and analytical problem-solving skills.
• Demonstrated ability to work hands-on with laboratory equipment and instrumentation.
• Ability to interpret complex datasets and connect measurements to physical mechanisms.
• Strong technical documentation and communication skills.
• Curiosity and willingness to develop proficiency across a broad range of FA techniques.

Responsibilities

• Perform hands-on failure analysis of electronic, semiconductor, and/or advanced technology devices and assemblies.
• Plan investigations by selecting appropriate analytical techniques and sequencing destructive and non-destructive methods.
• Perform and develop expertise in X-ray imaging and X-ray CT.
• Perform and develop expertise in SEM and EDS.
• Cross-sectioning, polishing, and sample preparation; Optical microscopy.
• Thermal and electrical localization techniques; Lock-in thermography where applicable.
• Acquire, process, visualize, and interpret experimental data; Distinguish signals from artifacts.
• Develop hypotheses for failure mechanisms and design experiments to confirm or reject them; Maintain clear experimental records and produce FA reports.

Skills

Hands-on engineering

Data interpretation

Analytical problem solving

Technical documentation

Communication

Curiosity

Education

BS in Materials Science

MS in Electrical Engineering

PhD in Physics

Tools

X-ray imaging

X-ray CT

SEM/EDS

Infrared / Thermography

Lock-in thermography

Python

MATLAB

LabVIEW

Data acquisition

Job description

We are seeking a hands-on Member of Technical Staff (MTS) – Failure Analysis Engineer to join the Failure Analysis (FA) team.

This role combines experimental work, instrumentation, data interpretation, and engineering problem solving. The successful candidate will investigate failures using multiple analytical techniques, develop evidence-based failure hypotheses, and communicate technically defensible conclusions.

Experience with lock-in thermography, thermal measurements, or related signal/data acquisition and interpretation techniques is particularly valuable.

As the individual develops in the role, they will take increasing ownership of customer interactions, including technical scoping, defining appropriate analysis strategies, and discussing results.

Key Responsibilities

• Perform hands-on failure analysis of electronic, semiconductor, and/or advanced technology devices and assemblies.
• Plan investigations by selecting appropriate analytical techniques and sequencing destructive and non-destructive methods.
• Perform and develop expertise in:
• X-ray imaging and X-ray CT
• SEM and EDS
• Cross-sectioning, polishing, and sample preparation
• Optical microscopy
• Thermal and electrical localization techniques
• Lock-in thermography, where applicable
• Acquire, process, visualize, and interpret experimental data.
• Distinguish meaningful signals from artifacts, noise, and measurement limitations.
• Correlate observations across multiple analytical techniques rather than relying on a single measurement.
• Develop hypotheses for failure mechanisms and design experiments to confirm or reject them.
• Maintain clear experimental records and produce technically rigorous FA reports.
• Learn new FA techniques and instrumentation as the team’s capabilities expand.
• Work safely and independently in a laboratory environment

Data Acquisition & Thermal Measurement Focus

The ideal candidate has experience in one or more of the following:

• Lock-in thermography or other modulated thermal measurement techniques
• Infrared imaging and thermography
• Signal processing, including filtering, averaging, phase/amplitude analysis, and signal-to-noise optimization
• Synchronous or lock-in detection
• Experimental data acquisition and instrumentation
• Understanding measurement uncertainty, resolution, sensitivity, calibration, and experimental artifacts
• Python, MATLAB, LabVIEW, or similar tools for data processing, visualization, or instrument control
• Direct lock-in thermography experience is desirable but strong experimental measurement and signal-analysis fundamentals can substitute for specific tool experience.

Customer & Technical Leadership Growth

With increasing experience, the MTS will:

• Interact directly with customers to understand technical problems and failure symptoms.
• Translate customer questions into effective FA strategies and scopes of work.
• Exp lain analytical capabilities, limitations, and tradeoffs.
• Present and discuss results with customers.
• Defend technical interpretations while clearly distinguishing observations, hypotheses, and conclusions.
• Recommend follow-up analysis when the available evidence does not support a definitive conclusion.

Qualifications

• BS, MS, or PhD in Materials Science, Electrical Engineering, Mechanical Engineering, Physics, Applied Physics, or a related technical discipline.
• Strong experimental and analytical problem-solving skills.
• Demonstrated ability to work hands-on with laboratory equipment and instrumentation.
• Ability to interpret complex datasets and connect measurements to physical mechanisms.
• Strong technical documentation and communication skills.
• Curiosity and willingness to develop proficiency across a broad range of FA techniques.

Preferred Experience

Experience with several of the following is advantageous:

• Semiconductor or electronics failure analysis
• Lock-in thermography / IR thermography
• X-ray CT
• SEM/EDS
• Metallographic preparation and cross-sectioning
• Optical microscopy
• Electrical fault localization
• Signal processing or scientific data analysis
• Automated data acquisition or instrument control
• Root-cause analysis and structured experimental design
• Customer-facing technical work

Covalent is a modern analytical services and engineering consulting company based in the San Francisco Bay Area (Sunnyvale). Our mission is to accelerate materials science innovation by serving as a problem-solving partner for technology leaders of all sizes and providing access to outstanding data generated quickly and cost-effectively.

• Covalent provides cutting-edge tools and expertise to equip our customers with the high-quality experimental data and insights they need to achieve their goals.

The pay range for this role is:

90,000 - 140,000 USD per year (Covalent Sunnyvale)