Senior Materials Process Engineer - ELYSIS

Alcoa of Australia Ltd; New Kensington (Westmoreland County); On-site; USD 110,000 - 150,000; Full time

Job summary

Alcoa is seeking a Senior Materials Process Engineer for the ELYSIS project at the New Kensington, PA facility. Lead development of ceramic electrode materials and guide R&D from pilot to commercial readiness, reporting to ELYSIS R&D management.

Responsibilities include process improvement, data‑driven optimization, and cross‑functional collaboration with operations, maintenance, quality, and external partners to ensure scalable, zero‑emission aluminum production technology success.

Qualifications

• Degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 1–5 years of relevant work experience in ceramic materials or processes.
• Strong knowledge of ceramic processing and processing equipment; scale‑up experience.

Responsibilities

• Develops and implements process improvement programs to reduce scale‑up and manufacturing risks.
• Leads process engineering projects to improve capability, stability, efficiency, and throughput.
• Provides data‑driven recommendations for process optimization and production readiness.
• Documents and standardizes process improvements through reports, SOPs and work instructions.

Skills

Ceramics processing

Project management

Materials characterization

Data analysis

Team collaboration

Education

Bachelor's degree in Materials Science & Engineering

Ceramics Engineering

Chemical Engineering

Job description

Shape Your World At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

Senior Materials Process Engineer – ELYSIS A New Era for the Aluminum Industry – ELYSIS Carbon Free Aluminum

There is a new, revolutionary way to make aluminum. It eliminates all greenhouse gases. And it produces oxygen! The ELYSIS™ technology is the greatest breakthrough in the aluminum industry since its beginnings in 1886. It has the potential to drastically reduce the environmental footprint of the global aluminum industry. The ELYSIS™ technology effectively puts an end to the use of carbon anode in the aluminum smelting process. It features the newly developed breakthrough proprietary materials that are stable and do not react during the process. Thus, it eliminates all direct greenhouse gas (GHG) emissions from the aluminum smelting process and is the first technology ever that emits oxygen as its by-product. An unprecedented world-class partnership of two major aluminum industry pioneers - Alcoa and Rio Tinto - led to the formation of ELYSIS, announced in 2018. The Canadian Government and the Quebec Government, through participation of Investment Quebec, have decided to support and be part of this industry revolution. The world’s technology giant Apple has helped facilitate the collaboration between Alcoa and Rio Tinto on the carbon-free smelting process and has agreed to provide ELYSIS with technical support. ELYSIS is headquartered in Montreal, Quebec, Canada with Technology Research & Development locations in Alma, Quebec, Canada, in Jonquière, Quebec, Canada, in New Kensington, Pennsylvania, United States, and in France. ELYSIS provides a unique solution for drastic reductions in the carbon footprint of many products used in our daily lives, including transportation, construction, electrical and consumer goods industries. ELYSIS metal is now being used by Apple (MacBook Pro and iPhone 12 SE), Ab InBEV (cans), Audi (e-tron GT wheels), and Corona (cans).

About the Location

The ELYSIS US Research & Development facility is in the Alcoa Technical Center (ATC) located in New Kensington, PA which is the birthplace of the aluminum industry. Near Pittsburgh, PA, the ATC is where the process being scaled-up by ELYSIS was first developed with a dedicated team who continues to reinvent the aluminum industry for a sustainable future.

About the position

The Senior Materials Process Engineer will use their wide breadth of knowledge and expertise in ceramic materials and processes to lead research and development efforts associated with technical readiness level advancement of a ceramic process used to produce proprietary and novel electrodes for the Elysis smelting process. This role also serves to be the technical liaison, providing data-based decisions, guidance, and support to Elysis electrode production and industrialization teams. This role will report to Elysis R&D management.

Key Activities / Responsibilities:

• Develops and implements process improvement programs focused on reducing scale-up, operational, and manufacturing risks associated with critical equipment and production processes.
• Leads process engineering projects by defining objectives, developing execution plans, and applying engineering analysis to improve process capability, stability, efficiency, and throughput across pilot and commercial operations.
• Provides data-driven recommendations for process optimization, equipment performance, production readiness, and operational reliability to support successful deployment and sustained operation of Elysis technology.
• Supports the development and refinement of process specifications, operating procedures, equipment requirements, and control strategies through continuous improvement initiatives and analysis of process performance data.
• Apply sound engineering principles and a hands‑on approach to troubleshoot process challenges, optimize production performance, and support manufacturing operations in laboratory, pilot, and commercial environments.
• Utilizes root cause analysis, statistical methods, and problem‑solving tools to identify, investigate, and implement sustainable corrective actions for process, equipment, quality, and production‑related issues.
• Identifies and leads initiatives that improve process efficiency, yield, reliability, product quality, capacity utilization, cost performance, and operational consistency.
• Collaborates with operations, maintenance, quality, R&D, suppliers, and external partners to ensure successful execution of process improvement projects while managing scope, schedules, budgets, and deliverables.
• Establishes and monitors key process performance indicators (KPIs), analyzes production data and trends, and develops actionable recommendations to improve process control and operational performance.
• Documents, communicates, and standardizes process improvements through technical reports, operating procedures, work instructions, presentations, and knowledge‑sharing activities to ensure long‑term process sustainability and organizational learning.

Mobility

ELYSIS is a global company with operations in Canada, France, and the United States. Business related travel and extended duration assignments or missions may be essential for the success of this role.

About You

• Degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
• 1-5 years of relevant work experience related to the development of ceramic materials or processes preferred.
• Demonstrated knowledge in ceramic processing, processing equipment and process scale‑up experience.
• Proven project execution and management skills.
• Strong aptitude in physical, chemical, and thermal material property characterization methods and analysis.
• Experience working in collaborative, results driven, fast‑paced team environments.
• Strong communication, organizational and analytical skills for data management, analysis, and results presentation.

Diversity: Be Part of an Unprecedented Partnership

At ELYSIS we are committed to an inclusive environment where people feel comfortable to be themselves. We want our people to feel that all voices are heard, all cultures respected and that a variety of perspectives are not only welcome – they are essential to success of the unprecedented partnership that ELYSIS is. We treat each other respectfully, fairly, compassionately and with dignity regardless of race, gender, nationality, ethnic origin, religion, age, sexual orientation, or anything else that makes us different. At ELYSIS, we particularly welcome and encourage applications from women, the LGBTQIA2 community, mature workers, people with disabilities and people from different cultural backgrounds. ELYSIS is proud to be an equal opportunity workplace.

About the Location

Every day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSIS™, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process– a revolution to the aluminum industry! We are values led, vision driven and united by our purpose of transforming raw potential into real progress. Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate. As a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person’s gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate. If you have visited our website in search of information on U.S. employment opportunities or to apply for a position, and you require an accommodation, please contact Alcoa Recruiting via email at [e-mail]. This is a place where you are empowered to do your best work, be your authentic self, and feel a true sense of belonging. Come join us and shape your career! Your work. Your world. Shape them for the better. Shape your Career at Alcoa! As an Alcoan you are part of a global team committed to advancing sustainability and delivering excellence and innovation. As a values-based company, we Act with Integrity, Operate with Excellence, Care for People, and Lead with Courage. Join us and become an essential part of our purpose: to turn raw potential into real progress. We treat all people with dignity and we believe in inclusion, diversity and enabling all employees to grow and develop their careers with us, where they can pursue their passions. Discover the possibilities a career with Alcoa can have for you. Come shape your career with us!

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