Senior Coating Engineer

Siemens Energy

Rural Hall (NC)

On-site

USD 120,000 - 150,000

Full time

27 hours ago

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Benefits offered by this job

Career growth

Supportive work culture

Health benefits

PTO & holidays

401K match

Family benefits

Parental leave

Job summary

Siemens Energy's Winston Technology Center seeks a Senior Coating Engineer to drive coating qualifications for gas turbine blades and vanes, lead automated thermal spray processes, and ensure production transfer.

You will collaborate with engineering, quality, maintenance, and supply chain; bring 7+ years in aerospace/coating tech; apply DOE, SPC, and 8D methodologies to deliver robust, scalable coating solutions for demanding power generation applications.

Qualifications

Bachelor's degree in Materials Science or Mechanical Engineering; PhD preferred.
7+ years in thermal spray and coating tech in aerospace, power generation, or gas turbine industries.
Experience leading coating qualifications and cross-functional engineering projects.
Strong expertise in APS, HVOF, VPS/LPPS, TBC and bond coats.
Experience with robotic programming and production integration in advanced manufacturing.
Familiarity with DOE, SPC, RCA, 8D, 5-Why and process qualification standards.

Responsibilities

Lead coating qualification activities from DOE to final engineering approval.
Develop and optimize thermal spray processes for TBC and bond coats.
Integrate robotic systems to improve torch orientation and cycle times.
Transfer qualified processes into production with operations and maintenance teams.
Conduct root cause investigations using 8D, 5-Why, and Fishbone methods; monitor SPC.
Partner across Engineering, Quality, and Supply Chain to drive continuous improvement.

Skills

Robotic programming

DOE

SPC

Project leadership

Thermal spray optimization

Cross-functional collaboration

Education

Bachelor's degree in Materials Science or Mechanical Engineering

PhD preferred

Tools

APS

HVOF

VPS/LPPS

Robotic automation systems

Path simulation

Job description

A Snapshot Of Your Day

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

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