Sr. Research Scientist (Metallurgy)

Armstrong World Industries•Lancaster, PA

3d•Onsite

About The Position

The Sr Research Scientist (Metallurgy) – Research & Development will be responsible for leading materials innovation for interior and exterior architectural metal systems by integrating metallurgy, surface engineering, coatings science, manufacturing processes, and durability performance. This individual will serve as the subject matter expert in metallurgy and metal mechanics - driving research and integration of metal substrates and surface technologies into building products. This position collaborates closely with Engineering, Manufacturing, Quality, Procurement, Marketing, Operations and interior and exterior metal business teams and reports to the R&D Manager – Coatings Science.

Requirements

Bachelor’s or Master’s degree in Metallurgy, Materials Science, Mechanical Engineering, or related field.
5+ years of experience in metal fabrication, finishing, or building materials R&D.
Strong understanding of: Physical metallurgy, Deformation mechanics, Metal forming processes, Surface engineering and coating systems, Corrosion science and durability
Experience with material characterization and analytical testing methodologies.
Experience with corrosion science and protective coating systems.
Experience working in or closely with manufacturing environments.
Proficiency in Microsoft Office and technical data analysis tools.
Ability to communicate complex technical information effectively.
Self-motivated with an innovative mindset and strong problem-solving skills.

Nice To Haves

PhD in Metallurgy, Materials Science, or related field.
Experience in architectural or exterior building products.
Knowledge of commercial construction practices and building codes.
Experience with ASTM and UL certification processes.
Participation in technical standards bodies (e.g., ASTM Committee G01).
Experience with CAD/FEA simulation for metal forming or structural analysis.
Familiarity with Agile project management.
Experience developing intellectual property and contributing to patent portfolios.

Responsibilities

Lead research and development of metal ceiling and wall systems utilizing aluminum, steel, and specialty alloys.
Apply principles of physical metallurgy, deformation mechanics, and metal forming science to improve structural integrity, flatness, dimensional stability, manufacturability, and long-term product performance.
Develop integrated material systems by evaluating interactions among alloy chemistry, fabrication methods, surface preparation, coatings, and environmental exposure.
Evaluate relationships between alloy selection, fabrication processes, surface condition, and subsequent finishing and corrosion performance.
Support optimization of bending, punching, roll forming, stamping, and fabrication processes while identifying opportunities where material selection or metallurgy can improve manufacturing robustness and product quality.
Evaluate the use of emerging and specialty alloys to improve performance, sustainability, durability, and aesthetics of existing and future architectural products.
Develop and optimize surface preparation processes including cleaning, pretreatment, conversion coatings, and surface activation.
Lead formulation and evaluation of finishes including patinas, clear coats, powder coatings, printing technologies, dye sublimation.
Evaluate and implement protective films and temporary coatings to preserve cosmetic quality during fabrication, shipping, and installation.
Lead failure analysis and root cause investigations associated with corrosion, coating failures, patina instability, discoloration, staining, and environmental degradation.
Design and interpret performance testing strategies that correlate accelerated laboratory testing with real-world exposure conditions and long-term field performance.
Guide development of surface protection systems for accelerated patina finishes, including alloy selection, conversion coatings, clear coats, and stable mineral phase development.
Develop technical guidance linking alloy selection, fabrication methods, surface preparation, finishing technologies, and environmental exposure conditions to expected product durability and service life.
Support product validation aligned with relevant standards (e.g., ASTM B117, ASTM G85, ASTM D3359, ASTM E84, UL, IBC).
Utilize advanced analytical techniques to evaluate metals and coatings, including: optical and electron microscopy, hardness testing, mechanical testing (tensile, fatigue, bend), adhesion and impact resistance testing, coating thickness and cure analysis.
Design and conduct experiments to assess performance under mechanical, thermal, and environmental stress conditions.
Analyze data and translate findings into actionable product improvements.
Assess technical and commercial viability of product concepts.
Develop business cases and de-risk technologies prior to plant implementation.
Support scale-up and ensure seamless transfer of technology into AWI manufacturing facilities.
Collaborate with strategic suppliers, finishing partners, fabricators, and technology partners to accelerate learning, validate technologies, and support commercialization of differentiated architectural metal solutions.
Incorporate sustainability considerations into alloy selection, coating systems, and process development (e.g., recycled content, low-VOC systems, durability for lifecycle extension).
Ensure all materials and processes meet health, safety, environmental, and building code requirements.
Stay current with industry standards and participate in technical committees where appropriate.
Maintain detailed records of research activities, formulations, and testing results.
Communicate findings through technical reports and presentations to both technical and non-technical stakeholders.
Contribute to patent development and AWI’s innovation pipeline.
Lead cross-functional technical projects from concept through commercialization.
Foster a culture of technical excellence, innovation, and continuous improvement.