Sr. Materials Engineer, Blades and Vanes R&D

SpaceX; Bastrop (TX); On-site; USD 120,000 - 180,000; Full time

Job summary

SpaceX in Bastrop, TX is seeking a Senior Materials Engineer for blades and vanes foundry to own complex materials challenges in a high-volume, fast-paced environment.

You will work with foundry engineering and operations to produce Ni-based superalloy castings for turbine components, performing experiments, analyses, and partner collaboration to improve performance and manufacturability.

Qualifications

• Bachelor’s degree in materials science, materials engineering, weld engineering, metallurgical engineering, or other engineering discipline.
• 5+ years of professional experience working in metal casting technologies.
• Experience with SX/DS Ni-based superalloy castings is preferred.
• Willingness to travel up to 15%.

Responsibilities

• Conduct applied research on SX, DS, and EQ cast components for gas turbines, focusing on casting processes, material properties, and performance.
• Investigate casting processes and parameters to improve quality, reliability, and manufacturability.
• Design and conduct experiments to evaluate casting processes, identify defects, and assess improvements.
• Analyze cast component failures and collaborate with design/process engineers to determine causes.
• Document methods, results, and recommendations to improve performance and manufacturability.

Skills

Metallurgical knowledge

Team collaboration

Problem solving

Communication

Education

Bachelor’s degree in materials/metallurgical engineering

Tools

SEM-EDS

Optical microscopy

Hardness testing

Mechanical property 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

• Conduct applied research on single crystal (SX), directionally solidified (DS), and equiaxed (EQ) cast components for gas turbines, focusing on the relationship between casting processes, material properties, and component performance.
• Investigate casting processes and process parameters to improve material quality, reliability, and manufacturability. These processes include core manufacturing, wax pattern manufacturing, shelling, solidification, core leaching, heat treat, HIP, machining, and coating methods
• Design and conduct experiments to evaluate casting processes, identify defects, and assess potential process improvements
• Analyze cast component failures arising during manufacturing or service, collaborating with design and process engineers to investigate underlying causes
• Conduct root cause investigations using fractography, metallography, and materials characterization techniques
• Evaluate material selection, material forms, tooling approaches, and material and process specifications to inform component design
• Develop and execute experimental test plans to characterize material properties and evaluate the performance of castings and foundry processes
• Collaborate with engineering teams, technicians, and external technical partners to exchange research findings and evaluate their practical application
• Document experimental methods, analyze results, and present recommendations to improve component performance, efficiency, durability, and manufacturability

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 PhD 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 engines
• 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 Affimative Action Plan for veterans and individuals with disabilities, or applicants requiring reasonable accommodation to the application/interview process should reach out to [e-mail].