Sr Engineer Materials -Aluminum Systems

Harley-Davidson•Milwaukee, WI

6d•$93,400 - $145,000•Onsite

About The Position

The Senior Materials Engineer is responsible for supporting the Product Development Process by providing deep technical expertise in aluminum materials, with a strong emphasis on cast aluminum components and systems. This role partners with product development, manufacturing, and suppliers to ensure robust material selection, processing, and performance. The engineer leads material-related problem solving, including failure analysis and root cause investigations, with a focus on improving aluminum casting quality and reliability in motorcycle applications. The candidate should be comfortable working with standard metallurgical and analytical tools to evaluate aluminum materials, including techniques such as optical emission spectroscopy, microscopy, and fractography. The ability to interpret results and connect laboratory findings to real-world component performance is essential. Candidate must be willing to perform preventive maintenance on lab equipment, plan for ordering necessary lab equipment, and keep track of budget expenses. This role serves as a technical advisor in aluminum materials, providing guidance across engineering teams and mentoring others as needed. The candidate must be able to communicate technical findings clearly and effectively to both technical and non-technical stakeholders.

Requirements

Bachelor’s degree in Materials Engineering, Metallurgy, or a related field is required.
A minimum of five years of experience in materials engineering is required.
Demonstrated hands-on experience in aluminum materials and casting processes, preferably in product development or manufacturing environments.
Applicants must be authorized to work in the United States.

Nice To Haves

Strong applied knowledge of aluminum alloys, including how composition, microstructure, and processing influence performance in real-world applications.
Expertise in aluminum casting processes such as high-pressure die casting, permanent mold casting, and sand casting, including an understanding of common defect modes, process controls, and quality risks.
Knowledge of heat treatment and thermal processing specific to aluminum alloys, including how these processes affect strength, durability, and dimensional stability.
Familiarity with corrosion behavior and surface treatments for aluminum is also expected, particularly as it relates to product durability and appearance.
Comfortable working with standard metallurgical and analytical tools to evaluate aluminum materials, including techniques such as optical emission spectroscopy, microscopy, and fractography.
Ability to interpret results and connect laboratory findings to real-world component performance is essential.

Responsibilities

Guide material selection and design decisions based on component requirements, particularly for structural and cosmetic cast aluminum parts.
Work closely with suppliers and manufacturing teams to improve casting quality, resolve defects, and support process development.
Lead technical failure analysis and root cause investigations related to aluminum components, including metallurgical evaluation, interpretation of lab results, and clear documentation of findings with actionable recommendations.
Support understanding of mechanical behavior, including fatigue performance, and how it relates to casting quality, defects, and service loading conditions.
Provide technical guidance to engineering teams, support supplier quality improvements, and ensure alignment between design intent and manufacturing capability.
Perform preventive maintenance on lab equipment, plan for ordering necessary lab equipment, and keep track of budget expenses.
Provide guidance across engineering teams and mentor others as needed.