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

doncastersexternalcareersite; Oxford (AL); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

PTO

Competitive 401K

Competitive medical insurance

Job summary

Doncasters in Oxford, Alabama, is seeking a Foundry Process Engineer to serve as the technical authority for VIM and directional solidification casting. You will own the thermal profiles, withdrawal mechanics, and metallurgical integrity to produce nickel-base superalloy turbine blades and vanes.

The role focuses on improving casting yield, eliminating microstructural defects, and ensuring process compliance to aerospace specs with an on-site, hands-on approach.

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science & Engineering or Mechanical Engineering from an accredited program.
• Minimum 3 years of direct engineering experience in a vacuum investment casting foundry.
• 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 with casting process simulation tools.

Responsibilities

• The Foundry Process Engineer / Process Owner serves as the primary technical authority for VIM and directional solidification/single crystal casting operations.
• Own the casting process from mold preheat through solidification, driving yield improvements and defect elimination.
• Maintain fixed process compliance to meet stringent aerospace component customer specifications.
• Work on-site at the Oxford, Alabama facility to ensure process integrity and product quality.

Skills

Metallurgical knowledge

Solidification kinetics

NDT grain inspection

Laue orientation

Minitab

Excel

Education

Bachelor’s degree in Metallurgical Engineering

Bachelor’s degree in Materials Science & Engineering

Bachelor’s degree in Mechanical Engineering

Tools

High-temperature vacuum equipment

Induction heating systems

PLC furnace controls

Casting process simulation tools

Job description

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].

An 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.