Senior Materials Development Engineer - ELYSIS

Alcoa of Australia Ltd; New Kensington (Westmoreland County); On-site; USD 120,000 - 160,000; Full time

Job summary

Alcoa Senior Materials Development Engineer – ELYSIS Carbon‑Free Aluminum leads R&D of ceramic electrodes for the ELYSIS process. The role acts as the technical liaison to production and industrialization teams, with most hands‑on work onsite at the Alcoa Technical Center in New Kensington, PA; remote documentation activities are supported.

The position requires a graduate degree in Materials Science & Engineering or Ceramics/Chemical Engineering, 5–10 years in ceramics, and strong project

Qualifications

• Graduate degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 5–10 years of experience developing ceramic materials or processes.
• Proven knowledge of ceramic sintering, processing equipment, and scale‑up.
• Strong project execution and management skills.
• Expertise in physical, chemical, and thermal material property characterization.
• Experience working in collaborative, results‑driven, fast‑paced teams.
• Excellent communication, organizational, and analytical skills.

Responsibilities

• Design and execute technical programs to reduce industrialization scale‑up risks for critical equipment and processes.
• Lead projects, develop objectives, work plans, and conduct research building on prior breakthroughs.
• Provide data‑based guidance for equipment and process design to lower risk associated with implementing the ELYSIS technology.
• Develop technical specifications for materials and commercial‑scale equipment, driving continuous improvement initiatives.
• Apply fundamental engineering principles in laboratory, pilot, and commercial‑scale environments.
• Use root‑cause analysis tools to resolve material, process, or production issues.
• Identify improvement opportunities and implement innovative solutions to advance materials development goals.
• Manage the scope, schedule, and budgets of vendors, service providers, and partner institutions.
• Document results in traceable formats; communicate progress through reports, presentations, patents, and publications.

Skills

Project management

Communication

Analytical skills

Organizational skills

Team collaboration

Education

Master's degree in Materials Science & Engineering

Ceramics Engineering

Chemical Engineering

Job description

Position Overview

Senior Materials Development Engineer – ELYSIS Carbon‑Free Aluminum at Alcoa. Lead research and development of ceramic electrodes for the ELYSIS smelting process, serving as the technical liaison to production and industrialization teams. Majority of work is hands‑on onsite at the Alcoa Technical Center in New Kensington, PA; remote documentation activities are supported.

Key Responsibilities

• Design and execute technical programs to reduce industrialization scale‑up risks for critical equipment and processes.
• Lead projects, develop objectives, work plans, and conduct research building on prior breakthroughs.
• Provide data‑based guidance for equipment and process design to lower risk associated with implementing the ELYSIS technology.
• Develop technical specifications for materials and commercial‑scale equipment, driving continuous improvement initiatives.
• Apply fundamental engineering principles in laboratory, pilot, and commercial‑scale environments.
• Use root‑cause analysis tools to resolve material, process, or production issues.
• Identify improvement opportunities and implement innovative solutions to advance materials development goals.
• Manage the scope, schedule, and budgets of vendors, service providers, and partner institutions.
• Document results in traceable formats; communicate progress through reports, presentations, patents, and publications.

Qualifications & Experience

• Graduate degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 5–10 years of experience developing ceramic materials or processes.
• Proven knowledge of ceramic sintering, processing equipment, and scale‑up.
• Strong project execution and management skills.
• Expertise in physical, chemical, and thermal material property characterization.
• Experience working in collaborative, results‑driven, fast‑paced teams.
• Excellent communication, organizational, and analytical skills.

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