Senior Coating Engineer

Siemens Gas and Power GmbH & Co. KG; Rural Hall (NC); On-site; USD 120,000 - 150,000; Full time

Benefits offered by this job

Career growth opportunities

Company paid health & wellness

Job summary

Siemens Energy is seeking a Senior Coating Engineer for the Thermal Spray & Robotics team at the Winston Technology Center in North Carolina. You will lead coating qualification programs, optimize APS and HVOF processes, and integrate robotic spray systems for gas turbine blades and vanes.

You will collaborate across Engineering, Quality, and Manufacturing to ensure production-ready coatings and continuous process improvements, guiding projects from development through production implementation.

Qualifications

• Bachelor's degree in a relevant engineering discipline is required; PhD preferred.
• 7+ years of experience in thermal spray and coating technology within aerospace, power generation, or gas turbine industries.
• Experience leading coating and process qualifications, robotic automation initiatives, and cross-functional projects.

Responsibilities

• Lead coating and process qualifications from DOE through engineering approval, supporting advanced qualification programs and documenting plans and specs.
• Develop and optimize thermal spray processes (APS, HVOF) and establish critical process windows for TBC and bond coats.
• Integrate robotic spray systems, optimize torch orientation, spray distance, and path planning to improve repeatability and cycle times.
• Transfer qualified coating processes into production with manufacturing and maintenance teams.
• Conduct root cause investigations using 8D, 5-Why, and Fishbone methods; monitor CpK and implement SPC.
• Collaborate with Engineering, Quality, and Supply Chain to monitor KPIs and drive continuous improvement for gas turbine coatings.

Skills

Thermal spray

Robotic programming

DOE

SPC

TBC coatings

Project leadership

Education

Bachelor's degree in Materials Science or Mechanical Engineering

Tools

APS

HVOF

VPS/LPPS

Robotic systems

Job description

\"We energize society\" by supporting our customers to make the transition to a more sustainable world, based on innovative technologies and our ability to turn ideas into reality. With nearly 100,000 employees around the world, we shape the energy systems of today and tomorrow.

As a Senior Coating Engineer with the Thermal Spray & Robotics team at the Winston Technology Center, you will support critical Advanced Coating Qualifications and help advance advanced manufacturing capabilities at Siemens Energy. Your primary focus will be driving process qualifications and technological applications for gas turbine blades and vanes while ensuring coating applications meet stringent engineering specifications and are successfully transitioned into production.

In this role, you will lead coating qualification activities, optimize thermal spray technologies, and support rigorous quality qualification processes. You will work closely with engineering, manufacturing, quality, and maintenance teams to develop qualified coating processes, integrate robotic automation solutions, and support production implementation.

The ideal candidate brings extensive experience in thermal spray processes, robotic programming, and qualification methodologies within the aerospace or power generation gas turbine industry. By combining strong engineering expertise with demonstrated project leadership, you will help advance thermal spray technology capabilities and support strategic coating qualification initiatives.

How You’ll Make an Impact

• Lead and execute coating and process qualifications from Design of Experiments (DOE) through final engineering approval, supporting critical Advanced Coating Qualification programs, including Orion coating qualifications, and developing process specifications, qualification plans, and technical documentation for component-level and system-level qualifications.
• Develop and optimize thermal spray processes, including APS and HVOF technologies, establishing critical process windows for thermal barrier coating (TBC) and bond coat applications while ensuring compliance with stringent engineering specifications.
• Integrate and optimize robotic thermal spray systems by improving torch orientation, spray distance control, turntable synchronization, coating uniformity, equipment repeatability, and cycle times through robotic programming and path simulation.
• Transfer qualified coating processes into production by collaborating with manufacturing and maintenance teams to ensure seamless operational integration and sustainable process performance.
• Perform root cause investigations using 8D, 5-Why, and Fishbone methodologies, while monitoring process capability (Cpk) and implementing Statistical Process Control (SPC) to reduce scrap and rework, optimize powder utilization, and improve overall process effectiveness.
• Partner with Engineering, Quality, and Supply Chain teams to establish and monitor key performance indicators, including first-pass yield and equipment uptime, while driving continuous improvement initiatives that advance Siemens Energy's thermal spray and robotic automation capabilities for gas turbine blades and vanes.

What You Bring

• Bachelor's degree in Materials Science, Mechanical Engineering, or a related engineering discipline required; PhD preferred.
• 7+ years of experience in thermal spray and coating technology within the aerospace, power generation, or gas turbine industry; candidates with a PhD and relevant thermal spray experience will also be considered.
• Demonstrated experience leading coating and process qualifications, robotic automation initiatives, and cross-functional engineering projects from development through production implementation.
• Strong expertise in thermal spray technologies, including APS, HVOF, and VPS/LPPS processes, as well as thermal barrier coatings (TBC), bond coats, and coating characterization techniques such as microstructure, porosity, and adhesion evaluation.
• Experience with robotic programming, path simulation, automated manufacturing systems, and production integration within an advanced manufacturing environment.
• Working knowledge of Design of Experiments (DOE), Statistical Process Control (SPC), root cause investigation methodologies, including RCA, 8D, and 5-Why, and process qualification standards.
• Proven technical project leadership skills with the ability to collaborate effectively across Engineering, Quality, Supply Chain, Manufacturing, and Maintenance organizations to drive qualification and continuous improvement initiatives.

About the Team

Our Gas Services division offers Low-emission power generation through service and decarbonization. Zero or low emission power generation and all gas turbines under one roof, steam turbines and generators. Decarbonization opportunities through service offerings, modernization, and digitalization of the fleet.

Who is Siemens Energy?

At Siemens Energy, we are more than just an energy technology company. With ~100,000 dedicated employees in more than 90 countries, we develop the energy systems of the future, ensuring that the growing energy demand of the global community is met reliably and sustainably. The technologies created in our research departments and factories drive the energy transition and provide the base for one sixth of the world's electricity generation. Our global team is committed to making sustainable, reliable, and affordable energy a reality by pushing the boundaries of what is possible. We uphold a 150-year legacy of innovation that encourages our search for people who will support our focus on decarbonization, new technologies, and energy transformation. Find out how you can make a difference at Siemens Energy: https://www.siemens-energy.com/employeevideo

Rewards

• Career growth and development opportunities
• Company paid Health and wellness benefits

Equal Employment Opportunity Statement

Siemens Energy and Siemens Gamesa Renewable Energy is an Equal Opportunity and Aff

All qualified applicants will receive consideration for employment without regard to their race, color, creed, religion, national origin, citizenship status, ancestry, sex, age, physical or mental disability unrelated to ability, marital status, family responsibilities, pregnancy, genetic information, sexual orientation, gender expression, gender identity, transgender, sex stereotyping, order of protection status, protected veteran or military status, or an unfavorable discharge from military service, and other categories protected by federal, state or local law.

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