Aluminum Metallurgist

ELLWOOD Aluminum•Hubbard, OH

10d•Onsite

About The Position

The Aluminum Metallurgist will serve as the subject matter expert (SME) for aluminum metallurgy, microstructural evaluation, and heat treatment protocols. This role involves overseeing and optimizing aluminum melting, refining, alloying, and casting processes. The Metallurgist will also direct non-destructive and destructive testing programs, lead root-cause failure analysis for casting defects, and partner with product design teams for R&D and innovation. Additionally, the position requires mentoring junior engineers and technicians, verifying raw material suppliers, and assisting the purchasing manager with supplier identification and evaluation. The role also emphasizes safety by ensuring compliance with plant safety regulations and promoting a safety culture.

Requirements

Bachelor of Science (B.S.) degree in Metallurgical Engineering, Materials Science and Engineering, or a closely related engineering discipline is required.
Minimum of 10 years of direct, hands-on metallurgical engineering experience within an aluminum foundry or aluminum casting environment.
Deep understanding of aluminum phase diagrams, grain refinement, modification chemistry (e.g., Strontium, Titanium-Boron), and degassing techniques.
Proficiency with metallurgical laboratory equipment, including optical microscopy, Scanning Electron Microscopy (SEM/EDS), and hardness testers.
Strong knowledge of international materials standards such as ASTM, AMS, SAE, and ISO.
Exceptional analytical, problem-solving, and technical writing skills.
Ability to communicate effectively with Operations, Quality, Engineering, Sales, suppliers, and customers.
Ability to interact directly with aerospace customer quality and engineering organizations.
Strong technical writing and presentation skills.
Ability to mentor, teach, train and transfer knowledge openly to those in positions where metallurgical specialties are part of career advancement.
Mentor/Coach/Train: Quality Technicians and production personnel in metallurgy, defect identification, process control, and problem solving.

Nice To Haves

Master’s (M.S.) or Ph.D. with a research focus on aluminum solidification or casting is highly preferred.
Licensed Professional Engineer (PE) credential is highly preferred.
American Society for Quality (ASQ) Certified Quality Engineer (CQE) or Six Sigma Black Belt is highly desirable.
Familiarity with ASNT Level II or III certifications (e.g., Liquid Penetrant, Ultrasonic, or Radiographic Testing) is a strong plus.
Active participation in professional societies like the American Foundry Society (AFS) or ASM International is preferred.
Certified Level II UT inspection per NAS 410.

Responsibilities

Oversee and optimize aluminum melting, refining, alloying, and casting processes (including high-pressure die casting, permanent mold, or sand casting).
Serve as the subject matter expert (SME) for aluminum metallurgy, microstructural evaluation, and heat treatment protocols.
Direct non-destructive testing (NDT) and destructive testing programs to guarantee product integrity and adherence to aerospace, automotive, or industrial specifications.
Lead complex root-cause failure analysis (RCFA) for casting defects (e.g., porosity, inclusions, hot tears) and implement robust corrective actions.
Partner with product design teams to develop new aluminum alloys and evaluate emerging casting technologies to improve mechanical properties and reduce costs.
Guide and mentor junior engineers, metallurgists, and laboratory technicians on best practices in foundry metallurgy.
Verify raw material suppliers, including hardeners and scrap.
Assist purchasing manager in identification of new suppliers and assist with ongoing rating of such suppliers.
Abide by all policies and procedures established by the Company including plant safety regulations and work rules.
Promote a safety culture and ensure compliance with safety policies and rules.
Provide for continuous reduction of workplace hazards, risks, employee accidents.