Lead Surface Preparation/Metallurgy Specialist

GE Vernova•Bangor, ME

14d•Onsite

About The Position

This role blends practical coating cell work, metallographic preparation, microstructural analysis, root-cause problem solving, and the design of fixtures/masking to enable repeatable, cost-effective production, all while operating within our SQDC (Safety, Quality, Delivery, Cost) values. You will work in a multi-disciplinary, multi-group environment, aligning R&D, manufacturing, quality, and customer teams toward a common goal, requiring clear, concise communication and strong collaboration skills.

Requirements

Bachelor’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, or related field
Minimum of 3 years of hands-on thermal spray process development experience (Thermal coatings)

Nice To Haves

Strong skills in coating microstructure evaluation and metallographic analysis (optical, image analysis).
Excellent written and verbal communication skills; proven track record working in multi-group environments toward shared goals.
Ability and desire to work on site in a manufacturing environment
Ability to work off-shift or flexible schedule at times as required by project timelines
Proven experience designing fixtures/masking for production coating applications (NX or equivalent CAD).
Background in process documentation, control plans, FMEA, and structured problem-solving (e.g., fishbone, 5Y, 8D).
Gas turbine or aerospace coatings qualification experience.
Knowledge of blasting, masking, heat treatment, and post-processing of coated parts.
Familiarity with nondestructive inspection (NDT) for coatings.
Lean/Six Sigma certification or equivalent continuous improvement experience.
Strong oral and written communication skills.
Demonstrated ability to analyze and resolve problems.
Ability to document, plan, market, and execute programs.
Established project management skills.

Responsibilities

Drive process development onsite, converting a ‘lab-proven’ parameters into stable and documented production processes.
Develop and qualify HVOF and Plasma coating processes.
The process transfer must be performed with a focus to the ‘Frozen Process’ standards to the thermal spray critical parameters and at the same time understanding the process levels of freedom to optimize the process meets the print and specification requirements.
Coating process development includes a large scope of operations such as masking, grit blasting, shot peen, final surface finish treatment.
Qualify inspections, post coating final surface finish, and heat treatments for bond coat and topcoat.
Capability to operate robotic thermal spray cells, solid understanding of thermal spray parameters and their influence on the coating process sustainability.
Validate robot programs, support robotic programming, and PLC I/O logic.
Identify potential ways to optimize the coating program to improve the cycle time or eliminate coating defects.
Thorough understanding of coating cell components and their interactions is required.
The candidate should be capable of diagnosing equipment or process issues and executing corrective and preventive actions to ensure long-term process stability.
In-depth expertise in microstructure evaluation and mechanical testing (hardness and tensile strength) is essential.
The candidate must be able to perform root cause analysis of coating defects (e.g., Contamination, poor adhesion, oxidation, cracking and voids) based on microstructural evidence, requiring a comprehensive understanding of how thermal spray process parameters affect coating microstructure.
Hands-on experience in a metallographic lab, including knowledge of the purpose and operation of standard laboratory equipment used in sample preparation and analysis.
Perform optical metallography, porosity, DVC microstructural features, microhardness testing to assess coating quality.
Develop and optimize, tooling, and masking to ensure repeatability, standoff control, and overspray containment.
Translate CAD concepts into tested, production-ready tooling solutions.
Responsible for process industrialization and scale-up activities based on Built in Quality, including creation of control plans, process gap identification, detailed work instructions, and comprehensive operator training materials.
Support implementation of SPC and lead NPI transfers, ensuring readiness for full-scale production and compliance with internal and external audits.
Partner with the process qualification team to determine coating process readiness by analyzing Cp and Cpk metrics.
Use insights from eCAV data to identify improvement opportunities and implement changes to enhance first-pass yield (FPY).
Lean Manufacturing & Process Flow. Leverage Lean manufacturing concepts such as takt time, value stream optimization, and waste reduction to enhance operational efficiency.
Work cross-functionally to implement workflows that improve throughput without compromising safety or product quality.
Collaborate across R&D, engineering, QA, operations, suppliers, and customers to ensure alignment on project goals and timelines.
Present complex data and insights in a clear, concise manner tailored to technical and non-technical stakeholders.

Benefits

medical
dental
vision
prescription drug coverage
access to Health Coach from GE Vernova, a 24/7 nurse-based resource
access to the Employee Assistance Program, providing 24/7 confidential assessment, counseling and referral services
GE Vernova Retirement Savings Plan, a tax-advantaged 401(k) savings opportunity with company matching contributions and company retirement contributions
access to Fidelity resources and financial planning consultants
tuition assistance
adoption assistance
paid parental leave
disability benefits
life insurance
12 paid holidays
permissive time off