Thermal Spray Industrialization & Process Development Engineer

GE Vernova • Greenville, SC

1d • Onsite

About The Position

Are you passionate about innovation? Are you excited at the opportunity to electrify and decarbonize the world? We operate with a founder’s mindset. We deliver innovation with passion, speed, and courage. We continuously challenge our thinking and are empowered to dream big and take smart risks. What impact you’ll make As a member of the Process Industrialization team, you will be an active contributor to create, maintain, and execute the standard in how to develop and industrialize manufacturing processes using a team-based approach. You will be responsible for the new coating process development and launch at the Greenville manufacturing plant. The focus will be on testing and developing new, or improving upon existing, manufacturing process by utilizing a standard framework. If you know how to turn a thermal spray coating into a rock-solid quality, repeatable production process, we want you. We’re seeking a hands-on highly experienced Thermal Spray Industrialization & Process Development Engineer to lead the development, qualification, industrialization, and serial life production. You will focus on High Velocity Oxy-Fuel (HVOF) and Atmospheric Plasma Spray (APS) coating processes for gas turbine high-performance components. This role blends practical coating cell work, metallographic preparation, microstructural analysis, root-cause problem solving, and the design of fixtures/masking to enable repeatable, cost-effective production, all while operating within our SQDC (Safety, Quality, Delivery, Cost) values. You will work in a multi-disciplinary, multi-group environment, aligning R&D, manufacturing, quality, and customer teams toward a common goal, requiring clear, concise communication and strong collaboration skills.

Requirements

• Bachelor’s degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering or related field (advanced degree preferred)
• Minimum 2 years of hands-on thermal spray process development experience in a manufacturing and project environment (HVOF & APS)
• Strong skills in coating microstructure evaluation and metallographic analysis (optical, image analysis)
• Excellent written and verbal communication skills; proven track record working in multi-group environments toward shared goals
• Ability and desire to work on site in a manufacturing environment.
• Ability to work off-shift or flexible schedule at times as required by project timelines
• Must be legally authorized to work in the USA without sponsorship now or in the future
• This position is 100% onsite at our GE Vernova Greenville, SC site
• This role is restricted to U.S. persons (i.e., U.S. citizens, permanent residents, and other protected individuals under the Immigration and Naturalization Act, 8 U.S.C. 1324b(a)(3)) due to access to export-controlled technology.
• GE will require proof of status prior to employment

Nice To Haves

• Minimum 4 years of hands-on thermal spray process development experience in a manufacturing and project environment (HVOF & APS).
• Proven experience designing fixtures/masking for production coating applications (SolidWorks, NX or equivalent CAD).
• Background in process documentation, FMEA, control plans, and structured problem-solving (e.g., fishbone, 5 Whys, 8D).
• Experience with MCrAlY bond coats, ceramic topcoats (e.g. YSZ), coatings.
• Gas turbine or aerospace coatings qualification experience.
• Knowledge of blasting, masking, heat treatment, and post-processing of coated parts.
• Familiarity with nondestructive testing (NDT) for coatings.
• Lean/Six Sigma certification or equivalent continuous improvement experience.

Responsibilities

• Industrialize and scale thermal spray coating processes to support GE Vernova’s largest volume expansion
• Develop, qualify, and industrialize HVOF and APS thermal spray processes from lab to full-scale production
• Understand the critical thermal spray parameters and ensure frozen process, repeatable production processes that meet print and specification requirements
• Operate and support thermal spray cells, including robotic spray programs, with a focus on quality, cycle time, and potential defect reduction and waste.
• Diagnose and resolve coating, equipment, and process issues to ensure long-term process stability
• Perform and interpret metallographic evaluations and mechanical testing to assess coating quality and lead root-cause analysis of defects
• Lead process scale-up activities, including control plans, work instructions, operator training, SPC, and NPI transfers
• Collaborate across engineering, operations, quality, and R&D to deliver results quickly in a high-volume manufacturing environment
• This role is 100% time on GE Vernova located in Greenville SC site

Benefits

• GE Vernova employees rise to the challenge of building a world that works. In order to meet this mission, we provide varied, competitive benefits to help support our workforce
• Our compensation & benefits are designed to reward high performers and help you manage your personal and family needs. We offer a robust benefits package depending on your employment status and your national requirements.
• A healthy, balanced lifestyle can mean different things to different people. We've created programs that support the way you live and work today.
• GE Vernova invests to provide opportunities to grow your career by providing a path for continued on-the-job learning and development.
• Available benefits include medical, dental, vision, and prescription drug coverage; access to Health Coach from GE Vernova, a 24/7 nurse-based resource; and access to the Employee Assistance Program, providing 24/7 confidential assessment, counseling and referral services.
• Retirement benefits include the GE Vernova Retirement Savings Plan, a tax-advantaged 401(k) savings opportunity with company matching contributions and company retirement contributions, as well as access to Fidelity resources and financial planning consultants.
• Other benefits include tuition assistance, adoption assistance, paid parental leave, disability benefits, life insurance, 12 paid holidays, and permissive time off.
• Relocation Assistance Provided: Yes

What This Job Offers

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