Sr Ceramic Materials Process Engineer — Carbon-Free Al

Alcoa; New Kensington (Westmoreland County); On-site; USD 110,000 - 170,000; Full time

Job summary

Alcoa is seeking a Senior Materials Process Engineer for the ELYSIS program at the New Kensington, PA site. You will lead R&D efforts on ceramic materials and contribute to the development and industrialization of electrode processes used in zero-emission aluminum production.

You will collaborate跨 functions with R&D, operations, and suppliers, applying data-driven decisions and scale-up know-how to advance technology readiness and process performance in a fast-paced environment.

Qualifications

• 1-5 years of relevant work experience preferred.
• Demonstrated knowledge in ceramic processing, processing equipment and scale-up experience.
• Proven project execution and management skills.
• Strong aptitude in physical, chemical, and thermal material property characterization methods and analysis.
• Experience in collaborative, results-driven, fast-paced team environments.
• Strong communication, organizational and analytical skills for data management, analysis, and results presentation.

Responsibilities

• Develops and implements process improvement programs focused on reducing scale-up risks in equipment and production.
• Leads process engineering projects by defining objectives, execution plans, and applying analysis to improve process capability and throughput.
• Provides data-driven recommendations for process optimization, equipment performance, and production readiness.
• Supports development of process specifications, procedures, equipment needs and control strategies through continuous improvement.
• Troubleshoots processes, optimizes production, and supports manufacturing across lab, pilot and commercial environments.
• Uses root-cause analysis and statistical methods to identify and implement corrective actions for process, equipment, quality, and production issues.
• Identifies and leads initiatives to improve efficiency, yield, reliability, and operational performance.
• Collaborates with operations, maintenance, quality, R&D, suppliers, and partners to ensure project success within scope, schedule, and budget.
• Establishes KPIs, analyzes production data, and develops actionable recommendations to improve control and performance.
• Documents and standardizes improvements through reports, SOPs, and knowledge sharing for long-term sustainability.

Skills

Years of experience

Ceramics processing knowledge

Project execution & management

Data management & analysis

Communication & organization

Analytical skills

Education

Degree in Materials Science Engineering or Ceramics/Chemical Engineering

Job description

Alcoa is seeking a Senior Materials Process Engineer for the ELYSIS program at the New Kensington, PA site. You will lead R&D efforts on ceramic materials and contribute to the development and industrialization of electrode processes used in zero-emission aluminum production.

You will collaborate跨 functions with R&D, operations, and suppliers, applying data-driven decisions and scale-up know-how to advance technology readiness and process performance in a fast-paced environment.