Senior Materials Engineer, Blades & Vanes Foundry

SPACE EXPLORATION TECHNOLOGIES CORP; Bastrop, Northern (TX, KY); Hybrid; USD 130,000 - 180,000; Full time

Job summary

SpaceX is seeking a Sr. Materials Engineer for Blades and Vanes Foundry in Bastrop, TX. You will conduct applied research on SX/DS/EQ cast components for gas turbines, focusing on casting processes, material properties, and performance.

Lead experiments, analyze failures, and collaborate with cross-functional teams to improve durability and manufacturability. The role requires advanced metallurgical expertise, strong communication, and the ability to work in a fast-paced, entrepreneurial

Qualifications

• Bachelor’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or related engineering discipline.
• 5+ years of professional experience in metal casting technologies.
• Master’s degree or PhD in material science or equivalent (preferred).
• Experience with SX or DS casting technologies using Ni-based superalloys (preferred).
• Experience with casting blades and vanes for industrial gas turbines or aerospace engines (preferred).
• 3+ years of metallographic characterization techniques and equipment (SEM-EDS, optical microscopy, hardness testing, etc.).

Responsibilities

• Conduct applied research on SX, DS, and EQ cast components for gas turbines, linking casting processes, material properties, and performance.
• Investigate casting processes and parameters to improve quality, reliability, and manufacturability.
• Analyze cast component failures and determine underlying causes with design/process engineers.
• Perform root cause investigations using fractography, metallography, and materials characterization.
• Evaluate material selection, forms, tooling approaches, and specifications to inform design.
• Develop and execute experimental test plans to characterize material properties and performance of castings.
• Collaborate with engineering teams and external partners to translate findings into practical applications.
• Document methods, results, and provide recommendations to improve performance, durability, and manufacturability.

Skills

Metal casting experience

SX/DS casting

Ni-based superalloys

Metallography

SEM-EDS

Optical microscopy

Hardness testing

Mechanical property testing

Spectroscopy techniques

Team collaboration

Education

Bachelor’s degree in material science

Master’s degree in materials engineering (preferred)

PhD in materials science or metallurgical engineering (preferred)

Tools

SEM-EDS

Optical microscopy

Hardness testers

Mechanical property testing equipment

Spectroscopy equipment

Job description

SpaceX is seeking a Sr. Materials Engineer for Blades and Vanes Foundry in Bastrop, TX. You will conduct applied research on SX/DS/EQ cast components for gas turbines, focusing on casting processes, material properties, and performance.

Lead experiments, analyze failures, and collaborate with cross-functional teams to improve durability and manufacturability. The role requires advanced metallurgical expertise, strong communication, and the ability to work in a fast-paced, entrepreneurial