Metals Process Engineer: CFD, Sintering & Heat Transfer

Vulcan Elements; Benson (NC); On-site; USD 90,000 - 120,000; Full time

Job summary

Vulcan Elements in the United States is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across process steps, delivering engineering insights for optimization. The role starts in Durham, NC and will move to Benson, NC upon facilities completion.

You will use ANSYS or COMSOL, explore CFD, heat transfer, and electromagnetic behavior, and collaborate with process and data engineers to translate modeling results into manufacturing guidance.

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 (e.g., Mechanical, Maxwell, ROCKY, Fluent), COMSOL Multiphysics, or equivalent commercial simulation software.
• Strong working knowledge of computational fluid dynamics (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 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 modeling

Heat transfer modeling

Mechanical stress analysis

Python scripting

MATLAB scripting

Independent work

Education

B.S. or higher in Mechanical Engineering, Aerospace Engineering, Materials Science and Engineering, or a closely related field

Tools

ANSYS

COMSOL Multiphysics

Job description

Vulcan Elements in the United States is seeking a Materials and Process Engineer with a metals focus to build and validate computational models across process steps, delivering engineering insights for optimization. The role starts in Durham, NC and will move to Benson, NC upon facilities completion.

You will use ANSYS or COMSOL, explore CFD, heat transfer, and electromagnetic behavior, and collaborate with process and data engineers to translate modeling results into manufacturing guidance.