Senior Engineer

Ellaway Blues Consulting; Dallas (TX); On-site; USD 90,000 - 115,000; Full time

Job summary

Ellaway Blues Consulting is looking for a Senior Metallurgical Engineer in Dallas, Texas. This role involves developing and optimizing high-temperature metallurgical processes for high-purity metals and alloys. The ideal candidate should have a Ph.D. in a related field and experience with molten salt electrolysis or metallothermic reduction. This position provides an opportunity to contribute to critical manufacturing capabilities in the U.S., emphasizing career development in a research-intensive environment.

Qualifications

• Ph.D. in Materials Science, Metallurgy, Chemical Engineering, Electrochemistry or related field.
• At least three years of hands-on experience with molten salt electrolysis or similar high-temperature process technologies.
• Experience with high-temperature metal and alloy production processes.

Responsibilities

• Lead the development and optimization of high-temperature metal and alloy production processes.
• Design and execute laboratory and pilot-scale experiments involving molten salts.
• Collaborate with R&D, manufacturing, quality, and EHS teams.

Skills

Molten salt electrolysis

Metallothermic reduction

Materials characterization

Process modeling

Analytical techniques

Education

Ph.D. in Materials Science, Metallurgy, Chemical Engineering, Electrochemistry or related field

Tools

XRD

XRF

SEM

LECO

Job description

We are seeking a Senior Metallurgical Engineer to join our client’s advanced materials and product engineering team in the Dallas–Fort Worth metro area. Our client is a well-established industrial manufacturer operating at the forefront of clean energy, robotics, and advanced materials, currently undergoing significant growth and expanding its domestic manufacturing capabilities.

This is a highly technical, hands‑on role focused on developing and scaling metallurgical processes used to produce high‑purity metals and alloys for high‑performance magnetic applications. The ideal candidate enjoys working in an environment that combines experimental research, process modeling, materials characterization, and pilot‑scale development to transform innovative concepts into production‑ready technologies.

Key Responsibilities:

• Lead the development and optimization of high‑temperature metal and alloy production processes.
• Design and execute laboratory and pilot‑scale experiments involving molten salts, reaction kinetics, and reduction pathways.
• Collaborate with R&D, manufacturing, quality, and EHS teams to support process development and commercialization.
• Characterize materials using analytical techniques such as XRD, XRF, SEM, and LECO.
• Engage with external research partners, universities, and government laboratories to advance technical capabilities.

The ideal candidate will hold a Ph.D. in Materials Science, Metallurgy, Chemical Engineering, Electrochemistry, or a related field. They will have at least three years of hands‑on experience with molten salt electrolysis, metallothermic reduction, or similar high‑temperature process technologies.

This is a high‑impact position within a rapidly growing organization offering excellent career development and the opportunity to help restore critical manufacturing capabilities in the United States. It is an outstanding opportunity for a technically driven engineer who thrives in a research‑intensive, hands‑on environment and is passionate about developing advanced materials technologies with national significance.