Metals Process Simulation Engineer

Energy Jobline ZR; Durham (NC); On-site; USD 100,000 - 150,000; Full time

Job summary

Vulcan Elements is seeking a Materials and Process Engineer to develop and validate computational models for thermal, fluid, and electromagnetic phenomena in magnet manufacturing. The role starts in Durham, NC, moving to Benson, NC as the new facility comes online.

You will build simulations with ANSYS/COMSOL, process data to optimize manufacturing steps, and collaborate with process, materials, and data engineers. Strong CFD, heat transfer, and scripting skills are essential.

Qualifications

• BS or higher in Mechanical Engineering, Aerospace Engineering, Materials Science, or related field.
• Experience building and validating process models using ANSYS/COMSOL or similar.
• Strong CFD, heat transfer, and stress/strain modeling knowledge.
• Python or MATLAB scripting for simulation setup and data 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 models for fluid dynamics, heat transfer, mechanical, and electromagnetic phenomena.
• Use models with process data to drive process improvement.
• Build and refine simulations using ANSYS, COMSOL, or equivalent.
• Collaborate with process, materials, and data engineers to integrate outputs.
• Design simulation studies to evaluate sensitivities and guide experiments.
• Document modeling assumptions, boundary conditions, validation results, and recommendations.
• Develop scripts and tools for pre/post-processing of simulation data.

Skills

CFD

Heat transfer modeling

Mechanical stress/strain analysis

Independent work

Cross-functional communication

Education

B.S. or higher in Mechanical Engineering or related field

Tools

ANSYS (Mechanical, Maxwell, ROCKY, Fluent)

COMSOL Multiphysics

Python

MATLAB

Job description

Vulcan Elements is seeking a Materials and Process Engineer to develop and validate computational models for thermal, fluid, and electromagnetic phenomena in magnet manufacturing. The role starts in Durham, NC, moving to Benson, NC as the new facility comes online.

You will build simulations with ANSYS/COMSOL, process data to optimize manufacturing steps, and collaborate with process, materials, and data engineers. Strong CFD, heat transfer, and scripting skills are essential.