Materials Process Engineer - Metals: CFD & Multiphysics

Vulcan Elements Inc.; North Carolina; On-site; USD 90,000 - 140,000; Full time

Job summary

Vulcan Elements Inc. is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across key manufacturing steps in Durham, NC, with a plan to move to Benson, NC upon facility completion.

You will apply CFD, heat transfer, and electromagnetic modeling to optimize processes, collaborating with process, materials, and data engineers and using ANSYS or COMSOL to deliver actionable manufacturing insights.

Qualifications

• B.S. or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a closely related field.
• Experience building and validating process models using ANSYS, COMSOL Multiphysics, or equivalent software.
• Strong working knowledge of CFD, heat transfer modeling, and mechanical stress/strain analysis.
• Proficiency with scripting languages (Python, MATLAB, or similar) for simulation setup, data extraction, and post-processing.
• Ability to work independently, manage multiple concurrent modeling efforts, and communicate results clearly to cross‑functional teams.

Responsibilities

• Model thermal conditions during manufacturing processes such as sintering, heat treatment, and casting.
• Create representative models for various manufacturing processes including fluid dynamics, mechanical behavior, heat transfer, and electromagnetic phenomena.
• Use models combined with process data to support process improvement and optimization.
• Build and refine simulations using ANSYS (Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation platforms.
• Collaborate with process, materials, and data engineers to integrate simulation outputs into process development and optimization workflows.
• Design simulation studies to evaluate process sensitivities, identify failure modes, and guide experimental campaigns.
• Document modeling assumptions, boundary conditions, validation results, and recommendations in a structured manner consistent with quality system requirements.
• Support development of custom scripts and automation tools (Python, MATLAB, or similar) for pre/post-processing of simulation data.

Skills

CFD knowledge

Heat transfer modeling

Mechanical stress/strain analysis

Analytical thinking

Independent work

Cross-functional communication

Education

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering or related field

Tools

ANSYS (Mechanical, Maxwell, ROCKY, Fluent)

COMSOL Multiphysics

Python

MATLAB

Job description

Vulcan Elements Inc. is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across key manufacturing steps in Durham, NC, with a plan to move to Benson, NC upon facility completion.

You will apply CFD, heat transfer, and electromagnetic modeling to optimize processes, collaborating with process, materials, and data engineers and using ANSYS or COMSOL to deliver actionable manufacturing insights.