Principal M&P Engineer, Metallics

Archer•San Jose, CA

1d•$219,000 - $273,700

About The Position

Archer is seeking an experienced Materials and Processes (M&P) Engineer to serve as the Metallics Subject Matter Expert for the airframe of its next-generation electric vertical takeoff and landing (eVTOL) aircraft. The aircraft is being certified under FAA airworthiness criteria derived from 14 CFR Part 23 and Part 21.17(b) for powered-lift. The role is the technical authority for metallic materials and processes across primary and secondary airframe structures, from alloy selection and specification development through qualification, production support, and FAA certification. This is a hands-on role on a fast-moving program. The successful candidate will bring deep metallurgical expertise, knowledge of aerospace specifications and certification requirements, and the ability to make timely decisions amid incomplete information and changing priorities. The role also helps build and mature Archer’s metallics M&P capability, including test methods, processes, tools, and mentorship of junior engineers.

Requirements

Bachelor’s degree in Metallurgical Engineering, Materials Science and Engineering, Mechanical Engineering, or a related field.
At least 8 years of aerospace M&P experience focused on metallic materials and processes, including direct support of metallic structures; 6 years is specified for candidates with an advanced degree.
Demonstrated experience leading material and process qualification, specification development, and FAA or equivalent EASA/military certification activities.
In-depth knowledge of aerospace aluminum alloys (2xxx, 6xxx, and 7xxx series and tempers), titanium such as Ti-6Al-4V, precipitation-hardening and corrosion-resistant steels such as 15-5PH, 17-4PH, A286, 440C, and 314, and low-alloy steels such as 4130, 4340, and 300M.
Strong understanding of heat treatment, microstructure-property relationships, fatigue, fracture mechanics, damage tolerance, stress corrosion cracking, and hydrogen embrittlement.
Working knowledge of special processes including heat treatment, anodizing and conversion coating, passivation, plating, shot peening, and welding and joining, with relevant aerospace standards cited in the posting.
Fluency with MMPDS, SAE AMS, ASTM, MIL, and NAS specifications, and galvanic compatibility guidance such as MIL-STD-889.
Experience with nondestructive testing methods, including dye penetrant, magnetic particle, ultrasonic, and eddy current testing, and defining acceptance criteria.
Familiarity with FAA regulations, Advisory Circulars, and M&P-related airworthiness requirements, including material and process control, fabrication methods, and material strength properties and design values.
Hands-on experience with fractography, metallography, and SEM/EDS for root-cause analysis.
Ability to work flexibly under changing priorities and perform under pressure.

Nice To Haves

Master’s degree or PhD.
Experience on a new aircraft development and type certification program, ideally in eVTOL, general aviation, or rotorcraft.
Experience with forgings and castings, including casting factors and classification such as AMS 2175.
Experience with metallic-composite hybrid structures, fastener systems, and bonded or sealed joints.
Experience conducting supplier audits and establishing or approving NADCAP-accredited special processes; AS9100 quality management system experience.
FAA DER or Designee experience, or experience working directly with Designees and FAA Aircraft Certification Offices.

Responsibilities

Serve as the M&P metallics subject matter expert and own material and process decisions for aluminum, titanium, steel, and corrosion-resistant alloys used in structures, engine and battery components, fittings, and fasteners.
Develop compliance data and substantiation for M&P-related airworthiness requirements; work with the FAA, DERs, and internal certification teams on certification activities.
Develop, author, and review internal M&P specifications, test plans, and other specifications.
Partner with stress, design, manufacturing, quality, supply chain, and certification teams to make timely trade-offs.
Help build and mature Archer’s metallics M&P capability, including laboratory test methods, processes, tools, and mentorship of junior engineers.
Plan and execute metallic material and process qualification programs, including test plans, test matrices, conformity, data review, and reports.
Establish material strength properties and design values using MMPDS and statistically based methods.
Author and maintain material and process specifications, design guidelines, and standards covering heat treatment, surface treatment, plating, shot peening, welding and joining, machining, and inspection requirements.
Lead alloy, temper, and product-form selection, balancing strength, fatigue and damage tolerance, corrosion resistance, weight, cost, and manufacturability.
Define corrosion prevention and control requirements, including galvanic compatibility, isolation of dissimilar materials, metal-to-composite interfaces, sealants, and finish systems.
Support manufacturing and suppliers with MRB dispositions, nonconformance resolution, first article inspections, special-process source approvals, and supplier audits.
Lead failure analysis and root-cause investigations using fractography, metallography, SEM/EDS, and hardness and conductivity testing, and drive corrective and preventive actions to closure.
Define metallic fatigue and damage tolerance methodology, including slow crack growth and safe-life, in coordination with the structures team.