Materials Engineer

Booz Allen Hamilton; Warren (MI); On-site; USD 69,000 - 158,000; Full time

Job summary

Booz Allen Hamilton is seeking a Materials Engineer to research, develop, and certify material solutions for ground vehicle survivability and performance. The role emphasizes ICME/AI-enabled discovery of alloys, coatings, and advanced materials with an emphasis on structural integrity and protection.

The candidate will conduct failure analyses, apply NDE methods, and translate microstructural data into design recommendations while collaborating across teams in a dynamic defense-focused

Qualifications

• 3+ years in materials selection, design, fabrication, and failure analysis.
• Experience supervising materials engineering and scientific efforts.
• Knowledge of advanced manufacturing and corrosion prevention.

Responsibilities

• Lead failure analysis investigations on vehicle components.
• Develop and apply NDE methods to inspect subsurface flaws.
• Relate material composition and microstructure to performance.
• Prototype and evaluate coatings for wear, corrosion, and EM control.
• Prepare technical reports and standardize material specs.

Skills

Materials selection

Design

Failure analysis

Advanced manufacturing

Corrosion prevention

ICME/AI modeling

Education

Bachelors in Engineering (Materials/Metals/Polymer/Ceramics)

Tools

Additive manufacturing

Automated material processing

NDE methodologies

Job description

Materials Engineer

The Opportunity:

Research, develop, characterize, and certify materials solutions to enhance ground vehicle survivability, mobility, lethality, and sustainment. Evaluate physical and chemical properties of materials, examine material performance under extreme operational environments, and drive advanced manufacturing innovations. Relate materials’ chemical compositions and microstructures to physical, material, and ballistic performance, and provide recommendations on the selection of optimal materials for structural integrity and protection. Leverage integrated computational materials engineering (ICME) and AI models to accelerate discovery of novel alloys, high-performance battery chemistries, and structural composite configuration. Evaluate and transition advanced manufacturing reclamation techniques. Develop and evaluate organic and inorganic surface coatings for wear resistance, signatures and electromagnetic control, and severe environment corrosion protection. Lead failure analysis investigations on vehicle components and determine root cause of failure and recommend design or processing modifications. Develop and apply Nondestructive Evaluation (NDE) methodologies to inspect materials for subsurface flaws. Develop technical reports and standardize material specifications.

You Have:

• 3+ years of experience in materials selection, design, fabrication, and failure analysis
• 3+ years of experience performing and supervising materials engineering and scientific efforts
• Knowledge of additive or advanced manufacturing and corrosion prevention and control
• Knowledge of processing, testing, and modeling composites, polymers, or ceramics, including lightweight high-performance composite or ceramic armor systems
• Ability to travel up to 15% of the time
• Ability to obtain a Secret clearance
• Bachelor’s degree in Engineering, Materials Engineering, Materials Science, Metallurgical Engineering, Polymer Engineering, or Ceramic Engineering

Nice If You Have:

• Experience diagnosing structural material failures under dynamic, blast, or fatigue loads
• Experience with advanced surface engineering, chemical corrosion mitigation, and environmental degradation testing
• Experience with cold spray technology or automated material processing
• Experience leveraging AI and ML databases for predictive materials design
• Knowledge of high-strength armor alloys, advanced metal fabrication, and phase transformations

Compensation

Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work-life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full-time and part-time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs. Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page. Salary at Booz Allen is determined by various factors, including but not limited to location, the individual’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract-specific affordability and organizational requirements. The projected compensation range for this position is $69,400.00 to $158,000.00 (annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of Booz Allen’s total compensation package for employees. This posting will close within 90 days from the Posting Date.

Identity Statement

As part of the hiring process, we will ask you to complete an identity verification process that leverages advanced biometrics and artificial intelligence to ensure authenticity and protect against identity fraud. You are expected to be on camera during interviews and assessments. We reserve the right to take your picture to verify your identity and prevent fraud.

Candidate AI Usage Policy

AI is a part of our daily work at Booz Allen, and we are committed to the responsible and ethical use of AI tools. However, we want to ensure a fair candidate process based on your own skills and knowledge. As part of this commitment, the use of artificial intelligence (AI) or other tools to assist with responses during interviews (whether in-person or virtual) is prohibited unless permission is explicitly provided.

Work Model

Remote: If this position is listed as remote, there may still be occasions when you are required to work in person at a Booz Allen or customer facility.

Hybrid: If this position is listed as hybrid, you will be expected to work from a Booz Allen or customer facility, in alignment with your leadership's expectations and the needs of the role.

Onsite: If this position is listed as onsite, work will primarily be performed full-time at a customer facility, where employees will collaborate directly with colleagues and customers as required by the role.

Commitment to Non-Discrimination

All qualified applicants will receive consideration for employment without regard to disability, status as a protected veteran or any other status protected by applicable federal, state, local, or international law.

All qualified applicants will receive consideration for employment without regard to disability, status as a protected veteran or any other status protected by applicable federal, state, local, or international law.

About Booz Allen

Booz Allen is an advanced technology company. We build commercial-grade products and solutions for America’s most critical defense, civil, and national security priorities.

Know Your Rights Poster Accommodations

Applicants who need a reasonable accommodation for any part of the application, hiring, or employment process because of a disability, a sincerely held religious belief, practice, or observance, or as otherwise required by applicable law should contact the Booz Allen Help Desk by calling 1-877-927-8278 or sending an email to [e-mail]. We will review requests on an individualized basis and provide reasonable accommodations consistent with applicable law.

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