Materials Engineer, Additive Manufacturing

SpaceX•Hawthorne, CA

21h•Onsite

About The Position

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars. Our Propulsion Materials team is responsible for developing and qualifying laser powder bed fusion (LPBF) processes for nickel-based superalloys used in next-generation rocket engines. In this role you will own process development, parameter optimization, and material characterization for high-performance components on Raptor engines. You will work daily with design and manufacturing teams to push the limits of what is possible with LPBF nickel superalloys and other materials. If you have significant hands-on experience developing and qualifying LPBF processes for nickel-based superalloys and want to apply that expertise to the most demanding propulsion applications, this is the role for you.

Requirements

Bachelor’s degree in materials engineering or other engineering discipline with emphasis on materials
1+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)

Nice To Haves

Master’s degree or PhD in materials engineering or related field
3+ years of professional work experience developing or qualifying laser powder bed fusion processes for nickel-based superalloys (e.g., Inconel 718, 625)
Direct experience with LPBF parameter development, build optimization, and post-processing (HIP, heat treatment, surface finishing)
Experience with metallurgical characterization and mechanical testing of additively manufactured nickel alloys
Experience with one or more of the following manufacturing methods: additive (laser powder bed fusion), direct energy deposition (DED), casting, forging, brazing, heat treating
Understanding of mechanical testing methods for metals including fracture and fatigue
Familiarity with standard testing methods for materials and development of design allowables
Experience with failure analysis and fractography including characterization techniques such as Scanning Electron Microscopy (SEM) and metallographic analysis
Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
Hands-on experience in a manufacturing environment
Understanding of non-destructive test methods for fracture control
Proven track record developing design allowables or material specifications for LPBF nickel alloys
Experience with fracture mechanics, fatigue, and creep testing of additively manufactured superalloys
Hands-on experience with process monitoring, in-situ sensors, or advanced process control for LPBF

Responsibilities

Provide materials and process support for propulsion system designs and manufacturing
Increase reliability of internal designs and manufacturing processes through material and process development
Develop physical, mechanical, and thermal properties for materials
Improve our additive processes and materials through characterization and development, with a primary focus on laser powder bed fusion of nickel-based superalloys
Work directly with our additive engineering and manufacturing teams daily
Perform root cause investigations using fractography, metallography, and testing
Provide technical reviews and advice for design efforts specifically related to drawings, specifications, and material requirements
Collaborate with other engineers, subject matter experts, and technicians to solve complex material and processing challenges on our current and next-generation vehicles