Senior Metallurgical Engineer - Failure Analysis & Materials Reliability

Phillips 66 • Bartlesville, OK

27d • $157,500 - $192,500

About The Position

The Senior Metallurgical Engineer works in Phillips 66’s Energy Research & Innovation organization to address materials reliability challenges and support the safe, reliable performance of refining, midstream, and renewable fuel assets. The role applies advanced scientific expertise to investigations, research, improved methods, and technical tools, translating findings into practical value across the company.

The engineer leads complex materials failure investigations and root-cause analyses; plans and manages a portfolio of research and technical support projects; designs and conducts experiments and testing; and applies diagnostic methods, laboratory techniques, software, simulation tools, and company-approved AI tools. The role also develops improved test methods and reusable standards, analyzes technical and business data, prepares reports and business cases, advises sites and stakeholders, and serves as a subject matter expert. It includes mentoring and reviewing colleagues’ work, monitoring external developments and regulations, contributing to technical publications and knowledge sharing, representing Phillips 66 in technical forums, and promoting safe laboratory and operating practices.

The position requires travel up to 5% and work around chemicals, including acids and bases. The base salary range is $157,500–$192,500. The posting states that eligible full-time employees may receive an annual variable cash incentive, an 8% company 401(k) match, a cash balance pension, medical, dental and vision benefits, a company contribution to a Health Savings Account for employees on an HDHP, and well-being programs and incentives.

Requirements

• Legally authorized to work in the job posting country.
• Bachelor’s degree or equivalent level in Materials Science & Engineering, Metallurgical Engineering, Mechanical Engineering, or a related scientific or engineering field.
• At least 6 years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis.
• At least 3 years of hands-on experience supporting refining, midstream, or renewable fuel assets.
• Travel up to 5% of the time.
• Ability to work around chemicals, including acids and bases.

Nice To Haves

• At least 10 years of experience in metallographic specimen preparation, corrosion damage mechanisms, welding techniques, optical and electron microscopy, hardness testing, fractography, and metallurgical failure analysis.
• At least 8 years of hands-on experience supporting refining, midstream, or renewable fuel assets.
• Strong working knowledge of corrosion mechanisms, materials degradation, welding and metallurgy, chemical treatment, coatings, fouling mitigation, or corrosion modeling.
• Experience conducting or supporting failure analysis, root-cause investigations, risk assessments, or laboratory corrosion studies.
• Experience with corrosion modeling or simulation tools such as COMSOL, Aspen HYSYS, OLI, or similar applications.
• Proficiency selecting, interpreting, and drawing conclusions from analytical techniques including XRF, XRD, CHN, IC, ICP, GCxGC-MS, GC-MS, SIMDIS, SEM, TGA, and optical microscopy.
• Experience using AI tools to support research, analysis, or technical problem-solving.
• Experience mentoring colleagues, critically reviewing work, guiding method development through influence, or representing an organization in external technical forums and industry consortia.
• Experience providing general supervision of more junior colleagues.
• Experience applying research methods, experimental design, data collection and analysis, and research and development testing.
• Experience using research databases, scientific software, laboratory equipment interfacing tools, or related technologies.
• Experience performing advanced data analysis, modeling, or simulation for scientific or technical problem-solving.

Responsibilities

• Lead complex materials failure investigations and root-cause analyses using metallography, fractography, and advanced materials characterization; identify failure mechanisms and recommend solutions.
• Plan and manage research and technical support projects, balancing priorities, resources, schedules, technical risk, and the needs of multiple sites and customers.
• Design and conduct experiments, testing, data collection, and analysis using appropriate research methods, and translate results into practical applications.
• Apply diagnostic methods, laboratory techniques, scientific software, simulation tools, and company-approved AI tools to investigate welding, corrosion, metallurgy, and other materials reliability challenges.
• Identify gaps in procedures, methodologies, and tools; develop improved test methods, diagnostic capabilities, and reusable standards.
• Analyze laboratory, field, process, and other data to assess business impacts, prepare reports, and develop business cases for investments in proactive investigations and research.
• Provide specialist advice on technical findings, standards, procedures, and emerging materials reliability issues.
• Serve as a subject matter expert in materials science, metallurgy, welding, and corrosion damage mechanisms; mentor colleagues, review technical work, and guide less experienced scientists and engineers.
• Monitor external developments, regulations, and industry practices; contribute to technical publications and knowledge sharing; represent Phillips 66 in technical forums; and promote safe laboratory and operating practices.

Benefits

• Annual Variable Cash Incentive Program bonus for eligible employees.
• 8% 401(k) company match.
• Cash Balance Account pension.
• Medical, dental, and vision benefits.
• Annual company contribution to a Health Savings Account for employees enrolled in an HDHP.
• Total well-being programs and incentives, including an Employee Assistance Plan, well-being reimbursement, and backup family care services.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior