Senior Materials & Process Engineer - Powder Metallurgy

Vulcan Elements; Durham (NC); On-site; USD 120,000 - 190,000; Full time

Job summary

Vulcan Elements in Durham, NC, United States, is seeking a Senior/Staff Materials and Process Engineer to lead end-to-end powder metallurgy for NdFeB magnets. You will optimize production, scale new alloy formulations, and drive defect investigations to improve magnetic performance and yield.

The role requires deep technical expertise in hydrogen decrepitation, jet milling, pressing, vacuum sintering, and post-sinter heat treatments, plus strong experience with SEM, XRD, TGA/DSC and DOE-style

Qualifications

• Bachelor’s/Master’s/Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline.
• 8+ years of hands‑on engineering experience in powder metallurgy processing (industrial manufacturing setting preferred).
• Experience with reactive metal powder processing, protective inert atmospheres, vacuum thermal processing, and advanced sintering kinetics.
• Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC
• Strong experience in design of experiments, statistical processing, and leading research efforts

Responsibilities

• Own and optimize the powder metallurgy pipeline, including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments.
• Correlate process variables to magnetic properties, microstructure, and part quality.
• Lead root-cause failure analyses for sample defects and implement corrective actions.
• Transition new alloy compositions from pilot scale to robust, high-volume production.
• Define technical specifications and partner with Manufacturing team for selection and commissioning of next-generation manufacturing equipment.

Skills

Powder metallurgy processing

Hydrogen decrepitation

Jet milling

Pressing and compaction

Vacuum sintering

Post-sinter heat treatments

Design of experiments

Statistical analysis

Python

MATLAB

JMP

Materials characterization

XRD

SEM

TGA/DSC

Education

Bachelor’s/Master’s/Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or related

Tools

ISO 9001

IATF 16949

Job description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency.

As a Senior/Staff Materials and Process Engineer, you will serve as the technical lead for the end-to-end powder metallurgy manufacturing process—spanning powder processing, advanced compaction, and thermal treatment. You will be responsible for optimizing current production lines, scaling new NdFeB magnet formulations, and troubleshooting complex materials anomalies. This role bridges the gap between R&D and high-volume production, ensuring maximum magnetic performance, microstructural integrity, and manufacturing yield. This is a high-impact, high-ownership role requiring deep technical expertise and leadership.

Responsibilities

• Own and optimize the powder metallurgy pipeline, including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments.
• Correlate process variables to magnetic properties, microstructure, and part quality.
• Lead root-cause failure analyses for sample defects and implement corrective actions.
• Transition new alloy compositions from pilot scale to robust, high-volume production.
• Define technical specifications and partner with Manufacturing team for selection and commissioning of next-generation manufacturing equipment.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Qualifications

• Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline.
• 8+ years of hands‑on engineering experience in powder metallurgy processing (industrial manufacturing setting preferred).
• Experience with reactive metal powder processing, protective inert atmospheres , vacuum thermal processing, and advanced sintering kinetics.
• Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC
• Strong experience in design of experiments, statistical processing, and leading research efforts

Must be a U.S. Person due to required access to U.S. export‑controlled information or facilities.

Preferred Qualifications

• Direct experience in the manufacturing of sintered NdFeB permanent magnets and grain boundary diffusion processes.
• Strong proficiency in evaluating magnetic materials properties and interpreting microstructural data.
• Experience utilizing data analysis tools (such as Python, MATLAB, or JMP) to analyze manufacturing quality datasets or automate performance mapping.
• Familiarity with ISO 9001 or IATF 16949 quality management standards.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.