Additive Manufacturing & Metallurgical Lead

Johns Hopkins Applied Physics Laboratory • Laurel, MD

8d

About The Position

Would you like to be part of a highly technical, collaborative, and multifaceted team with expertise that spans the disciplines of aerospace, mechanical engineering, and physics?
Do you enjoy solving challenges related to materials science and its applications in missile systems?
Do you have a passion for finding solutions to current and emerging materials challenges for the Department of Defense (DoD)?
If so, then we’re looking for someone like you to join our Materials Engineering section!
As a section our mission focuses on innovation, integration, and characterization of materials for missile defense. We operate at the intersection of material innovation, modeling, damage mitigation, and energetics. Joining this section means working with state-of-the-art facilities, subject matter experts, and a supportive team of materials scientists and engineers.
With a focus on advanced propulsion, next generation interceptors and structural integrity, we are seeking a subject matter expert in Metallurgy and Additive Manufacturing (AM) to revolutionize the production of aerospace propulsion and structural systems. This role is central to the development of future defensive missiles and other high-performance projectiles. By leveraging Directed Energy Deposition (DED) and novel alloy design, you will create components that are lighter, stronger, and more heat-resistant than legacy hardware, directly impacting the kinematic reach and lethality of US defense systems.
As a Additive Manufacturing & Metallurgical Lead you will....

Requirements

• Possess an BS in Metallurgical Engineering, Materials Science and Engineering or Materials Engineering, with a minimum of five years of related experience
• Have demonstrated hands-on expertise with metal additive manufacturing and alloy designs platforms
• Have a strong background in physical metallurgy and hands-on expertise with DED and powder-bed fusion platforms
• Are able to correlate micro-structural evolution during the AM process with macro-scale performance in extreme aerospace environments
• Have excellent communication skills to interface with sponsors, contractors, and Program Managers
• Can obtain an interim Secret-level security clearance by your start date and can ultimately obtain a Secret-level clearance. If selected, you will be subject to a government security clearance investigation and must meet the requirements for access to classified information. Eligibility requirements include U.S. citizenship

Responsibilities

• Alloy Innovation: Design and qualify proprietary alloys for metal 3D printing that provide enhanced structural integrity at temperatures exceeding current industry standards
• Propulsion Enhancement: Apply additive manufacturing to create complex, high-efficiency rocket nozzles and engine components that enable greater interceptor speed and maneuverability
• Multi-Functional Materials: Develop reactive structural materials and metallized fuels that integrate structural support with enhanced energetic performance
• Failure Analysis & Mitigation: Use advanced characterization and techniques to predict damage growth mechanisms from EMP, kinetic impact, and thermal stress in printed components
• Advanced Infrastructure: Oversee the fabrication of resilient defense infrastructure components, utilizing AM to reduce maintenance cycles and improve system-level reliability
• Alloy Engineering: Develop and optimize metal powders and feedstock for AM/DED processes, focusing on improving creep resistance and thermal stability
• Advanced Manufacturing: Lead efforts in Directed Energy Deposition to create complex, multi-functional geometries for aerospace propulsion and structural systems
• Mechanical & Chemical Evaluation: Evaluate material performance under combined loads, including kinetic, thermal, and chemical stressors
• Damage Assessment: Analyze damage growth mechanisms in printed parts, specifically looking at high-velocity impact and environmental degradation (e.g., oxidation)
• Mission Support: Contribute to the development of reactive structural materials to enhance the kinematic capabilities and lethality of missile/projectile systems

Benefits

• Our employees enjoy generous benefits, including a robust education assistance program, unparalleled retirement contributions, and a healthy work/life balance.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level