Metals Materials Process Engineer: CFD Modeling

Vulcan Elements; Durham (NC); On-site; USD 90,000 - 130,000; Full time

Job summary

Vulcan Elements in Durham, NC is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across key process steps, supporting product development. The role requires expertise in CFD, heat transfer, and electromagnetic behavior, plus experience with ANSYS or COMSOL.

You will collaborate with process, materials, and data engineers to turn simulation results into manufacturing guidance and contribute to a rapid, quality-driven development workflow as

Qualifications

• BS or higher in Mechanical, Aerospace, or Materials Engineering
• Experience building and validating process models using ANSYS/COMSOL or equivalent
• Strong knowledge of CFD, heat transfer, and mechanical stress/strain
• Python or MATLAB scripting for simulation setup and post-processing
• Ability to work independently and communicate results to cross-functional teams

Responsibilities

• Model thermal conditions during manufacturing processes such as sintering, heat treatment, and casting
• Create representative models for various processes including CFD, mechanical behavior, heat transfer, and electromagnetic phenomena
• Use models 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

Heat transfer

Stress analysis

Python

MATLAB

Education

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Aerospace Engineering

Bachelor's degree in Materials Science and Engineering

Tools

ANSYS

COMSOL Multiphysics

Fluent

Job description

Vulcan Elements in Durham, NC is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across key process steps, supporting product development. The role requires expertise in CFD, heat transfer, and electromagnetic behavior, plus experience with ANSYS or COMSOL.

You will collaborate with process, materials, and data engineers to turn simulation results into manufacturing guidance and contribute to a rapid, quality-driven development workflow as