Foundry Process Engineer / Process Owner (DS/SX Casting)

Socket.dev; Oxford (AL); On-site; USD 85,000 - 120,000; Full time

Benefits offered by this job

PTO

401K

Medical insurance

Job summary

Doncasters in Oxford, Alabama seeks a Foundry Process Engineer to be the primary technical authority for VIM and directional solidification/single crystal casting. You will own the casting process from mold preheat through solidification, driving yield improvements and defect elimination while ensuring aerospace specifications are met.

The role requires a metallurgical engineering background, 3+ years in vacuum investment casting, and hands-on experience with high-temperature vacuum equipment

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science & Engineering, Mechanical Engineering or related discipline.
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Responsibilities

• The Foundry Process Engineer owns the casting process from mold preheat through solidification to improve yield and meet customer specs.
• The role drives metallurgical integrity, thermal profiles, withdrawal mechanics and process compliance.

Skills

Vacuum casting experience

Physical metallurgy

Solidification kinetics

NDT data interpretation

Laue / crystal orientation

Statistical tools (Minitab, Excel)

High-temp vacuum equipment

Education

Bachelor’s degree in Metallurgical Engineering / Materials Science & Engineering / Mechanical Engineering

Tools

Minitab

Excel

Casting process simulation tools

Job description

Are you seeking a new career as a Process Engineer with a focus on DS/DX Casting? Could you act as the primary technical authority for the vacuum induction melting (VIM) and directional solidification/single crystal casting operations?

At Doncasters we have an exciting opportunity for a Process Engineer to join our team in Oxford, AL.

The working hours/salary for this role are Monday through Friday 7:30 AM to 4:30 PM.

Why join us?

Did you know that every time you take a flight, drive somewhere, or switch on a light, there’s a chance Doncasters played a part in making that happen?

We are a specialist manufacturer of complex precision cast components for aerospace engines and industrial gas turbines, supporting leading OEM programs.

We excel in turning metals into motion, working in alloys and manufacturing complex product designs to offer an unparalleled range of solutions for high performance and specialist applications.

We employ more than 3,000 people across 14 core manufacturing facilities globally, providing the scale and expertise required to serve leading aerospace engine and IGT OEMs.

At Doncasters, we believe in doing things the right way. That means acting with integrity, delivering with commitment, and working as one team to achieve more, together. Whether you're developing precision-engineered components, running world-class manufacturing operations, or supporting our people and processes, your role is part of something much bigger.

Join us and contribute to a legacy built on performance, precision, and the values that drive us forward - excellence, commitment, integrity, and teamwork.

What we can offer you:

• An interesting and varied field to work in
• An environment where you can learn and grow through constant development opportunities
• PTO
• Competitive 401K
• Competitive medical insurance

The Role

The Foundry Process Engineer / Process Owner serves as the primary technical authority for the vacuum induction melting (VIM) and directional solidification/single crystal casting operations. Located on-site at our Oxford, Alabama, aerospace investment casting facility, this critical role is responsible for the thermal profiles, withdrawal mechanics, and metallurgical integrity required to produce advanced nickel-base superalloy turbine blades and vanes. The engineer owns the casting process from mold preheat through solidification, driving casting yield improvements, microstructural defect elimination, and fixed process compliance to meet stringent aerospace component customer specifications.

Interested?

If you have any of the below skills, we would love to talk to you about your next career move:

• Bachelor’s degree in Metallurgical Engineering, Materials Science & Engineering, Mechanical Engineering or related discipline from an accredited program.
• Minimum 3 years of direct engineering experience in a vacuum investment casting foundry, with an understanding of manufacturing facility operations.
• Fundamental understanding of physical metallurgy and solidification kinetics, including dendritic nucleation and growth.
• Hands‑on familiarity with high-temperature vacuum equipment, induction heating systems, and PLC furnace controls.
• Proficiency in interpreting NDT grain inspection data, crystal orientation alignment (Laue), and microstructure analysis.
• Advanced capability in statistical software (Minitab, Excel) and familiarity of casting process simulation tools.

Equal opportunities

Doncasters is committed to achieving workforce diversity and we pride ourselves on creating an inclusive working environment. We welcome all applications irrespective of social and cultural background, national origin, race, age, sex, gender identity, disability- physical or hidden, sexual orientation, veteran status, religious belief, or any other characteristics protected by law. We provide a fully inclusive and accessible recruitment process. We encourage all applicants to reach out if they require any support or accommodations to enable them to thrive throughout our recruitment process. Please contact [e-mail].

QualificationsAn ambitious individual who has a proven track record in Industrial Gas Turbine (IGT) castings experience in a Turbine Aerofoils industry. Ideally you will have a working knowledge of materials science, mechanical, or industrial engineering along with specific investment casting experience.

If you are a Process Engineer looking to deploy your skills in an established business then we would love to hear from you.