Senior Metallurgical Engineer - Failure Analysis & Materials Reliability

Phillips 66; Bartlesville (OK); On-site; USD 157,000 - 193,000; Full time

Benefits offered by this job

VCIP bonus

401k match

Pension

Medical/Dental/Vision

Well-being programs

Job summary

Phillips 66 is seeking a Senior Metallurgical Engineer – Failure Analysis & Materials Reliability to solve complex materials reliability challenges across refining, midstream, and renewable assets. You will lead investigations, design experiments, and translate results into practical solutions for enterprise-wide impact.

You will apply advanced diagnostic methods and AI tools, mentor colleagues, and contribute to technical publications while ensuring safe laboratory practices.

Qualifications

• Bachelor’s degree in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering or a related scientific or engineering field.
• 6+ years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis
• 3+ years of hands-on experience supporting refining, midstream, or renewable fuel assets
• Travel up to 5% of the time
• Work around chemicals, including acids and bases

Responsibilities

• Lead complex materials failure investigations and root-cause analyses using metallography, fractography, and advanced materials characterization.
• Plan and manage a portfolio of research and technical support projects across sites and customers.
• Design and conduct experiments, testing, data collection, and analysis to evaluate technical problems.
• Apply advanced diagnostic methods and AI tools to investigate welding, corrosion, metallurgy, and other materials reliability challenges.
• Develop improved test methods, diagnostic capabilities, and reusable standards.
• Analyze data to prepare reports and business cases supporting investments in proactive investigations.
• Provide specialist advice on technical findings, standards, procedures, and emerging materials reliability issues.
• Mentor colleagues and represent Phillips 66 in technical forums.

Skills

Metallurgical expertise

Failure analysis

Data analysis

Research experience

Education

Bachelor’s degree in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering or related field

Tools

COMSOL

Aspen HYSYS

OLI

XRF

XRD

CHN

ICP

GCxGC-MS

GC-MS

SIMDIS

SEM

TGA

Optical microscopy

Job description

Phillips 66 & YOU - Together we can fuel the future

As a Senior Metallurgical Engineer - Failure Analysis & Materials Reliability, in our Energy Research & Innovation organization, you’ll help solve complex materials reliability challenges to support the safe, reliable performance of our refining, midstream, and renewable fuel assets. This is an opportunity to apply advanced scientific expertise, shape better methods and tools, and turn insights into practical value across the enterprise.

What You’ll Do

• Lead complex materials failure investigations and root-cause analyses, using metallography, fractography, and advanced materials characterization to identify failure mechanisms and recommend solutions.


• Plan and manage a portfolio of research and technical support projects, balancing priorities, resources, schedules, technical risk, and the needs of multiple sites and customers.


• Design and conduct experiments, testing, data collection, and analysis using appropriate research methods to evaluate technical problems and translate results into practical applications.


• Apply advanced diagnostic methods, laboratory techniques, scientific software, simulation tools, and company-approved AI tools to investigate welding, corrosion, metallurgy, and other materials reliability challenges.


• Identify gaps in existing procedures, methodologies, and tools; develop improved test methods, diagnostic capabilities, and reusable standards that strengthen the quality and efficiency of technical support.


• Analyze laboratory, field, process, and other data to assess business impacts, prepare clear reports, and develop business cases that support investments in proactive investigations and research.


• Provide specialist advice on technical findings, standards, procedures, and emerging materials reliability issues, enabling sites and stakeholders to make informed decisions.


• Serve as a subject matter expert in materials science, metallurgy, welding, and corrosion damage mechanisms; mentor colleagues, review technical work, and provide guidance to less experienced scientists and engineers.


• Monitor external developments, regulations, and industry practices; contribute to technical publications and knowledge sharing, represent Phillips 66 in technical forums, and promote safe laboratory and operating practices.

What You’ll Bring - Required

• Legally authorized to work in the job posting country


• Bachelor’s degree or equivalent level in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering or a related scientific or engineering field


• 6 or more years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis


• 3 or more years of hands‑on experience supporting refining, midstream, or renewable fuel assets


• Travel up to 5% of the time


• Work around chemicals, including acids and bases

What Makes You Stand Out - Preferred

• 10 or more years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis


• 8 or more years of hands‑on experience supporting refining, midstream, or renewable fuel assets


• Strong working knowledge of corrosion mechanisms, materials degradation, welding and metallurgy, chemical treatment, coatings, fouling mitigation, or corrosion modeling


• Experience conducting or supporting failure analysis, root‑cause investigations, risk assessments, or laboratory corrosion studies


• Experience with corrosion modeling or simulation tools such as COMSOL, Aspen HYSYS, OLI, or similar applications


• Proficiency selecting, interpreting, and drawing conclusions from analytical techniques including XRF, XRD, CHN, IC, ICP, GCxGC-MS, GC-MS, SIMDIS, SEM, TGA, and optical microscopy


• Experience using AI tools to support research, analysis, or technical problem‑solving


• Experience mentoring colleagues, critically reviewing work, guiding method development through influence, or representing an organization in external technical forums and industry consortia


• Experience providing general supervision of more junior colleagues


• Experience applying research methods, experimental design, data collection and analysis, and research and development testing


• Experience using research databases, scientific software, laboratory equipment interfacing tools, or related technologies


• Experience performing advanced data analysis, modeling, or simulation for scientific or technical problem‑solving

Compensation Range

This position has a base salary range of $157,500 – $192,500.

Total Rewards

Benefits

At Phillips 66, providing access to high quality programs and care for you and your family is important to us. Maintaining a culture of well‑being — physical, emotional, social, and financial — is essential for a high‑performing organization. When we are at our best, we are poised to deliver exceptional results — personally and professionally. Benefits for certain eligible, full‑time employees include:

• Annual Variable Cash Incentive Program (VCIP) bonus


• 8% 401k company match


• Cash Balance Account pension


• Medical, Dental, and Vision benefits with an annual company contribution to a Health Savings Account for employees on HDHP


• Total well‑being programs and incentives, including Employee Assistance Plan, well‑being reimbursement, and backup family care services

Learn more about Phillips 66 Total Rewards.

Phillips 66 has more than 140 years of experience in providing the energy that enables people to dream bigger and go farther, faster. We are committed to improving lives, and that is our promise to our employees and our communities. We are sustained by the backgrounds and experiences of our diverse teams, which reflect who we are, the environment we create and how we work together. We have been recognized by the Human Rights Campaign, U.S. Department of Labor and the Military Times for our continued commitment to inclusive practices and policies in the hiring and retention of those in the LGBTQ+ community and military veterans. Our company is built on values of safety, honor and commitment. We call our cultural mindset Our Energy in Action, which we define through four simple, intuitive behaviors: We work for the greater good, cultivate an environment of trust, seek different perspectives and pursue excellence.

Learn more about Phillips 66 and how we are working to meet the world's energy needs today and tomorrow, by visiting phillips66.com.

To be considered

In order to be considered for this position you must complete the entire application process, which includes answering all prescreening questions and providing your eSignature on or before the requisition closing date of 10/27/2026.

Candidates for regular U.S. positions must be a U.S. citizen or national, or an alien admitted as permanent resident, refugee, asylee or temporary resident under 8 U.S.C. 1160(a) or 1255(a)(1). Individuals with temporary visas such as E, F-1, H-1, H-2, L, B, J, or TN or who need sponsorship for work authorization now or in the future, are not eligible for hire.

Phillips 66 is an Equal Opportunity Employer