Sr. Materials Engineer, Blades and Vanes Foundry

SpaceX; Bastrop (TX); On-site; USD 140,000 - 190,000; Full time

Job summary

SpaceX seeks a Senior Materials Engineer for Blades and Vanes Foundry to lead development and production of SX, DS, and EQ castings using Ni-based superalloys for gas turbines and aerospace engines.

You will troubleshoot casting processes, perform failure analyses, and collaborate across design, process, and supply chain to optimize performance, reliability, manufacturability, and cost.

Qualifications

• Bachelor’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or other engineering discipline.
• Master’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or equivalent (preferred).

Responsibilities

• Accelerate progress on development and production of SX (single crystal), DS (directionally solidified), and EQ (equiax) casted components for gas turbines.
• Develop, qualify and troubleshoot metal casting processes used in production.
• Execute failure analysis of casted components and drive yield improvement in collaboration with design and process engineers.
• Perform root cause investigations using fractography, metallography, and characterization techniques.
• Provide technical review and advising for design efforts related to material alloy and form selection, tooling, and material/process specifications.
• Drive property development and qualification test plan design and execution for castings and foundry processes.
• Coordinate with engineering teams, supply chain, vendors, operations, technicians, and leadership to align on performance, reliability, manufacturability, and cost.

Skills

Cross-functional collaboration

Troubleshooting

Fractography techniques

Education

Bachelor’s degree in Materials Engineering or related

Master’s degree in Materials Engineering (preferred)

Tools

SEM-EDS

Optical microscopy

Hardness testing

Spectroscopy

Job description

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.

SR. MATERIALS ENGINEER, BLADES AND VANES FOUNDRY

SpaceX continues to revolutionize the launch industry by combining advanced technological developments with pragmatic and lean manufacturing. This is especially important for the future of rapid and high-volume Starship flight, where power generation is crucial. As a member of the Materials Engineering team, you will own solving complex materials challenges in a rapidly innovating environment. You will interact closely with foundry engineering and operations teams, and have direct impact on producing Ni-superalloy castings for power generation, ultimately ushering in the next era of revolutionary spaceflight.

Responsibilities

• Accelerate progress on development and production of SX (single crystal), DS (directionally solidified), and EQ (equiax) casted components for gas turbines
• Develop, qualify and troubleshoot metal casting processes used in production
• Execute failure analysis of casted components as a result of process fallout and/or in-service failures, working in tandem with design and process engineers to drive yield higher
• Perform root cause investigations using fractography, metallography, and characterization techniques
• Provide technical review and advising for design efforts as it relates to material alloy and form selection, tooling, and material and process specifications
• Drive property development and qualification test plan design and execution and of castings and foundry processes
• Responsible for coordinating with various engineering teams, supply chain, vendors, operations, technicians, and senior leadership on a consistent basis to stay aligned on product performance, reliability, manufacturability, and cost requirements
• Drive improvements to design via feedback on manufacturability, performance, efficiency, and product life to optimize business needs

Basic Qualifications

• Bachelor’s degree in material science, materials engineering, weld engineering, metallurgical engineering, or other engineering discipline
• 5+ years of professional experience working in metal casting technologies

Preferred Skills And Experience

• Master's degree or Ph.D. in material science, materials engineering, weld engineering, metallurgical engineering, or equivalent engineering discipline
• 5+ years of professional experience with SX or DS casting technologies using Ni-based superalloys
• Experience working on casting blades and vanes for industrial gas turbines or aerospace enignes
• 3+ years of experience with metallographic characterization techniques and equipment, such as SEM-EDS, optical microscopy, hardness testers, mechanical property testing, and/or spectroscopy techniques for composition or phase
• Strong interpersonal and collaborative skills with enthusiasm for the team’s spirit of innovation in cutting-edge technology
• Experience with technical review of material processes and a first principles understanding of how process variables impact material performance
• Demonstrated track record of success in a rapidly growing, fast-paced and highly competitive environment
• Personality and drive to execute in a scrappy entrepreneurial environment that operates under tight timelines and aggressive schedules
• Hands-on experience in a high-production manufacturing environment
• Effective written and interpersonal communication skills

Additional Requirements

• Willingness to travel to other SpaceX sites and/or vendors (up to 15%)
• Ability to lift up to 30 Ibs unassisted
• Standing/walking for long periods of time
• Willingness to work long hours and weekends as necessary to accommodate manufacturing and test campaigns

Itar Requirements

• To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C.
• 1157, or (iv) Asylee under 8 U.S.C.
• 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.

SpaceX is an Equal Opportunity Employer; employment with SpaceX is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Applicants wishing to view a copy of SpaceX’s AffReady Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to [e-mail].