Senior Metallurgist - Alloy Design & Advanced Manufacturing

The Johns Hopkins University Applied Physics Laboratory; Laurel (MD); On-site; USD 100,000 - 245,000; Full time

Job summary

The Johns Hopkins University Applied Physics Laboratory in Laurel, MD seeks a Senior Metallurgist - Alloy Design & Advanced Manufacturing to lead the design, processing, and characterization of novel metals across the full development cycle.

You will apply computational thermodynamics, experimental campaigns, and advanced manufacturing to tailor materials for performance and manufacturability, connecting composition, processing, and properties for real-world applications.

Qualifications

• MS in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or related field.
• 3+ years of relevant experience in physical metallurgy, alloy development, or advanced manufacturing.
• Demonstrated experience in alloy design, processing, heat treatment, and processing-structure-property relationships in metallic materials.
• Experience using Thermo-Calc, CALPHAD, or related computational materials tools to guide alloy or process development.
• Hands-on experience with metallurgical processing and characterization, including microscopy, diffraction, and mechanical testing.
• Ability to independently define technical approaches, interpret results, and work in multidisciplinary teams.
• Active Secret security clearance; U.S. citizenship required.

Responsibilities

• Develop processing strategies for conventional and additive manufacturing.
• Design and develop advanced structural alloys.
• Establish processing-structure-property relationships to guide material development.

Skills

Materials science MS

3+ years experience

Alloy design

Thermo-Calc/CALPHAD

Metallurgical processing

Security clearance

Education

MS in materials science

Tools

Thermo-Calc

CALPHAD

Job description

Description

Are you interested in designing and developing new alloys for demanding applications?

Do you have experience leveraging metallurgy to understand how composition and processing control material performance?

Are you interested in translating new alloy concepts into manufacturable materials using conventional and advanced manufacturing processes?

We are seeking a Senior Metallurgist - Alloy Design & Advanced Manufacturing to lead the design, processing, and characterization of novel metals. This role will combine computational thermodynamics, experimental alloy development, and advanced manufacturing to develop materials tailored to specific performance and manufacturing requirements. You will work across the full materials development cycle: from defining alloy compositions and processing windows through manufacturing, heat treatment, characterization, and performance evaluation.

As a Senior Metallurgist - Alloy Design & Advanced Manufacturing, you will...

1. Develop processing strategies for conventional and additive manufacturing

• • Develop processing plans that connect alloy composition, solidification, thermomechanical processing, and heat treatment to desired microstructures and properties.
  • Design and evaluate alloys for additive manufacturing, accounting for rapid solidification, thermal cycling, segregation, defect formation, and process-specific constraints.
  • Establish processing windows and heat-treatment strategies that enable reproducible material performance and translation from laboratory-scale alloy development toward manufacturing.

1. Design and develop advanced structural alloys

• • Use computational thermodynamics and materials modeling tools such as Thermo-Calc/CALPHAD to explore composition space, predict phase stability and transformations, and guide experimental alloy development.
  • Design alloys around application-specific combinations of mechanical performance, environmental resistance, temperature capability, manufacturability, and material availability.
  • Plan and execute experimental campaigns to validate computational predictions and iteratively refine alloy compositions and processing conditions.

1. Establish processing-structure-property relationships to guide material development

• • Develop characterization strategies using techniques such as SEM/EDS, EBSD, XRD, optical microscopy, and mechanical testing to understand alloy behavior.
  • Connect composition and processing history to phase evolution, microstructure, defects, and resulting material performance.
  • Use experimental results to identify mechanisms, refine alloy and process designs, and guide subsequent material development.

Qualifications

You meet our minimum qualifications if you...

• Have an MS in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline.
• 3+ years of relevant experience in physical metallurgy, alloy development, or advanced manufacturing.
• Have demonstrated experience in alloy design, processing, heat treatment, and processing-structure-property relationships in metallic materials.
• Have experience using Thermo-Calc, CALPHAD, or related computational materials tools to guide alloy or process development.
• Have hands-on experience with metallurgical processing and characterization, including relevant microscopy, diffraction, and mechanical testing techniques.
• Are able to independently define technical approaches, interpret experimental results, and work effectively within multidisciplinary research teams.
• Hold an active Secret security clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship.

You’ll go above and beyond if you...

• Have a PhD in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related discipline with research focused on alloy design, physical metallurgy, or advanced manufacturing.
• Have significant experience developing alloys specifically for additive manufacturing or other advanced manufacturing processes.
• Have experience designing, processing, and characterizing refractory alloys or other high-temperature metallic systems.
• Have experience with compositionally or functionally graded materials, including gradient alloy design and characterization of composition-microstructure-property relationships.
• Have demonstrated experience taking a material from initial alloy concept through processing, characterization, testing, and manufacturing demonstration.

About Us

Why Work at APL?

The Johns Hopkins University Applied Physics Laboratory (APL) brings world-class expertise to our nation's most critical defense, security, space and science challenges. While we are dedicated to solving complex challenges and pioneering new technologies, what makes us truly outstanding is our culture. We offer a vibrant, welcoming atmosphere where you can bring your authentic self to work, continue to grow, and build strong connections with inspiring teammates.

At APL, we celebrate our differences of perspectives and encourage creativity and bold, new ideas. Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance. APL's campus is located in the Baltimore-Washington metro area. Learn more about our career opportunities at https://www.jhuapl.edu/careers.

All qualified applicants will receive consideration for employment without regard to race, creed, color, religion, sex, gender identity or expression, sexual orientation, national origin, age, physical or mental disability, genetic information, veteran status, occupation, marital or familial status, political opinion, personal appearance, or any other characteristic protected by applicable law. APL is committed to providing reasonable accommodation to individuals of all abilities, including those with disabilities. If you require a reasonable accommodation to participate in any part of the hiring process, please contact [e-mail].

The referenced pay range is based on JHU APL's good faith belief at the time of posting. Actual compensation may vary based on factors such as geographic location, work experience, market conditions, education/training and skill level with consideration for internal parity. For salaried employees scheduled to work less than 40 hours per week, annual salary will be prorated based on the number of hours worked. APL may offer bonuses or other forms of compensation per internal policy and/or contractual designation. Additional compensation may be provided in the form of a sign-on bonus, relocation benefits, locality allowance or discretionary payments for exceptional performance. APL provides eligible staff with a comprehensive benefits package including retirement plans, paid time off, medical, dental, vision, life insurance, short-term disability, long-term disability, flexible spending accounts, education assistance, and training and development. Applications are accepted on a rolling basis.

Minimum Rate

$100,000 Annually

Maximum Rate

$245,000 Annually