Failure Analysis Engineer

Samsung SDI America Inc.•Auburn Hills, MI

About The Position

The Failure Analysis Engineer conducts battery failure investigations to identify root causes through analytical testing and laboratory experiments. The role supports testing, operates laboratory equipment, and collaborates with cross-functional teams to drive corrective actions. It also includes technical reporting and maintaining a safe, well-managed laboratory environment. The engineer leads investigations into battery failures such as cell ruptures, thermal runaway events, capacity fade, and other performance issues. The role examines failed cells, modules, and packs using visual inspections, non-destructive testing, and materials analysis; analyzes relevant test and environmental data; and designs experiments to validate hypotheses and simulate failure conditions. The position manages laboratory equipment and consumables, arranges battery disposal after testing, and documents findings in comprehensive technical reports. It communicates results and recommendations to engineering, quality assurance, product development, and other partners. The role also requires compliance with quality-system requirements, company health and safety procedures, and applicable risk assessment and incident reporting processes.

Requirements

Problem-solving ability and detail-oriented analytical skills, including critical thinking and troubleshooting complex issues.
Attention to detail in documentation and reporting to ensure the integrity and reliability of failure-analysis results.
Adaptability to evolving technologies and commitment to continuous learning.
Ability to work independently and collaboratively in a fast-paced, dynamic environment.
Ability to manage multiple projects concurrently and prioritize tasks effectively.
Ability to perform routine physical activities, including lifting, carrying, and moving materials.
Bachelor's degree in Chemistry, Chemical Engineering, Material Engineering, Electrical Engineering, or a related field.
Comply with company quality-system requirements and health and safety procedures, including PPE use, risk assessment, and hazard and incident reporting.

Nice To Haves

Experience in battery failure analysis, reliability engineering, or a related field, particularly with lithium-ion batteries or similar energy storage systems.
Expertise in battery technologies and associated systems.
Methodological knowledge of root cause analysis; practical experience is a plus.
Experience operating analytical equipment such as CT and SEM/EDX.
Experience working in a multicultural environment.
Communication and presentation skills, including the ability to convey technical concepts and findings to technical and non-technical audiences.
Bachelor's degree in Chemistry, Chemical Engineering, Material Engineering, Electrical Engineering, or a related field (listed as preferred education).

Responsibilities

Lead investigations into battery failures, including cell ruptures, thermal runaway events, capacity fade, and other performance issues, using analytical techniques and testing methodologies.
Examine failed battery cells, modules, and packs through visual inspections, non-destructive testing, and materials analysis to identify failure modes and mechanisms.
Analyze investigation data, including voltage/current profiles, temperature measurements, and environmental conditions, to determine root causes.
Develop hypotheses and perform root cause analyses to identify contributing factors such as manufacturing defects, design flaws, material degradation, or operational issues.
Design and execute experiments and tests to validate hypotheses and simulate failure conditions, including accelerated aging, thermal cycling, and abuse testing such as overcharge and over-discharge.
Collaborate with internal and external partners, including research institutions and testing laboratories, to conduct specialized testing and analyses as needed.
Manage laboratory equipment and maintain an environment conducive to accurate analysis and evaluation.
Procure laboratory consumables required for battery analysis and manage battery disposal after testing.
Document failure-analysis findings, including failure modes, root causes, and contributing factors, in comprehensive technical reports.
Communicate results and recommendations to cross-functional teams, including engineering, quality assurance, and product development, to drive corrective actions and improvements.
Comply with the Quality Operating System in accordance with ISO 9001:2008; identify concerns and initiate corrective and preventive or continuous-improvement actions relating to products, processes, and quality systems.
Follow company safe work procedures and departmental or supervisory OH&S directions; use and maintain appropriate PPE and safety systems.
Assist with preparation of risk assessments and conduct them with relevant staff, researchers, and the supervisor before work or research begins.
Report OH&S problems, workplace hazards, and work-related injuries or illnesses through the applicable reporting processes.
Lead incident investigations and implement corrective actions.
Perform routine physical activities, including lifting, carrying, and moving materials.