Sr. Materials Engineer, Blades and Vanes R&D

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