Senior Materials and Process Engineer, Powder Metallurgy

Job overview

The Senior Materials and Process Engineer, Powder Metallurgy role is onsite in Durham, NC, with regular presence on the production floor. Compensation is not specified. Vulcan Elements manufactures American rare-earth permanent magnets for national security, economic resiliency, and critical industries. The engineer leads and optimizes powder metallurgy processes, connects process variables to material and part performance, and resolves production issues. The role bridges research and development with high-volume manufacturing by scaling new magnet formulations and improving yield, quality, and production capability.

What you'll do

• Own and optimize powder metallurgy processes including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments
• correlate process variables with magnetic properties, microstructure, and part quality
• lead root-cause failure analyses and corrective actions
• transition alloy compositions from pilot scale to high-volume production
• define technical specifications and partner with Manufacturing on equipment selection and commissioning.

What we're looking for

Skills & competencies

senior materials engineer

process engineer

powder metallurgy

rare-earth magnets

ndfeb

manufacturing process

materials characterization

durham nc

vulcan elements

8+ years experience

production floor

u.s. person required

pilot-to-production

root-cause analysis

Work arrangement

• Weekend coverage required

Why this role

Requires a bachelor’s, master’s, or Ph.D. in a related technical discipline and 8+ years of hands-on powder metallurgy engineering experience. Must be a U.S. Person due to access to export-controlled information or facilities. Experience with sintered NdFeB magnets is preferred.

About the employer

Vulcan Elements is hiring for this role. Industry: Secondary Smelting, Refining, and Alloying of Nonferrous Metal (except Copper and Aluminum). Sector: 33.