Senior Materials & Process Engineer - Powder Metallurgy
Vulcan Elements · Research Triangle Park, NC
- Level
- Senior
- Team
- Process
- Degree
- Required
- Experience asked
- 8+ years
- Industry
- Metals
- Posted
- 30+ days ago
The role in 30 seconds
A senior process role at Vulcan Elements (metals) in Research Triangle Park, NC. You will serve as the technical lead for the end-to-end powder metallurgy manufacturing process—spanning powder processing, advanced compaction, and thermal treatment.
- They ask for
- 8+ years · degree required
- Tools it names
- Root cause, DOE, ISO 9001, IATF 16949
Read from the posting. The full description is below.
How this role compares
Against 28 other live process postings in North Carolina.
- Experience asked
- More than usual (8+ vs 5+)
Similar roles usually ask 5+ years.
Skills these teams ask for most
- ✓ Root cause 28%
- SPC 28%
- Six Sigma 24%
- FDA / GMP 21%
- Tooling 21%
- ✓ DOE 21%
✓ = this posting asks for it too. % = share of similar postings that mention it.
Stands out: this posting asks for ISO 9001, Python, which few similar roles mention. If you have it, lead with it.
At a glance
Pulled from the posting text. If it's not listed here, the posting didn't say.
How to get in at this plant
Five moves over a week or two. The first one takes ten minutes.
- 1
Pick 2–3 people on the Process team at Vulcan Elements
We found 1 person at this company and state: 1 leaders, plus 1 likely hiring manager. Engineers who joined in the last year or two reply the most. See them ↓
- 2
Send a short, curious note
One real question about their work. No favors yet. Each person gets a different note, written for this role.
Write to Jesse → (free) - 3
Turn a reply into a short call
Questions worth asking about this team:
- What does a normal week look like on your team?
- Is the work mostly new product launches or sustaining existing lines?
- How much time do you spend on the floor versus at a desk?
- How did you land the job? What stood out in your interviews?
- 4
Apply with someone vouching for you
If the call went well, ask whether they’d pass your résumé to the hiring manager. Send your résumé link, apply that day, and let them know.
- 5
Bring proof to the interview
One page of before-and-after numbers from projects you led: scrap, OEE, cycle time, cost. Plant managers hire on results.
This plant: Vulcan Elements in Research Triangle Park
9 other open roles at this site · 1 person we found on the process team.
- Controls Technician · Controls · Technician
- Product Quality Engineer · Quality
- Staff Process Engineer · Process · Senior
- Controls Engineer · Controls
- Sr. Controls Engineer · Controls · Senior
- Sr. Quality Engineer · Quality · Senior
Full description from Vulcan ElementsAs posted on their careers site.ShowHide
Responsibilities
- ◆Own and optimize the powder metallurgy pipeline, including hydrogen decrepitation, jet milling, pressing and compaction, vacuum sintering, and post-sinter heat treatments.
- ◆Correlate process variables to magnetic properties, microstructure, and part quality.
- ◆Lead root-cause failure analyses for sample defects and implement corrective actions.
- ◆Transition new alloy compositions from pilot scale to robust, high-volume production.
- ◆Define technical specifications and partner with Manufacturing team for selection and commissioning of next-generation manufacturing equipment.
Responsibilities
and tasks outlined are not exhaustive and may change as determined by the needs of the business.
Qualifications
- ✓Bachelor’s, Master’s, or Ph.D. in Materials Science, Metallurgical Engineering, Chemical Engineering, or a related technical discipline.
- ✓8+ years of hands-on engineering experience in powder metallurgy processing (industrial manufacturing setting preferred).
- ✓Experience with reactive metal powder processing, protective inert atmospheres , vacuum thermal processing, and advanced sintering kinetics.
- ✓Experience with materials characterization and analytical techniques such as SEM, XRD, TGA/DSC
- ✓Strong experience in design of experiments, statistical processing, and leading research efforts
Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.
Preferred Qualifications
- ✓Direct experience in the manufacturing of sintered NdFeB permanent magnets and grain boundary diffusion processes.
- ✓Strong proficiency in evaluating magnetic materials properties and interpreting microstructural data.
- ✓Experience utilizing data analysis tools (such as Python, MATLAB, or JMP) to analyze manufacturing quality datasets or automate performance mapping.
- ✓Familiarity with ISO 9001 or IATF 16949 quality management standards.
Physical and Environmental
Requirements
The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.
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Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency.
As a Senior/Staff Materials and Process Engineer, you will serve as the technical lead for the end-to-end powder metallurgy manufacturing process—spanning powder processing, advanced compaction, and thermal treatment. You will be responsible for optimizing current production lines, scaling new NdFeB magnet formulations, and troubleshooting complex materials anomalies. This role bridges the gap between R&D and high-volume production, ensuring maximum magnetic performance, microstructural integrity, and manufacturing yield. This is a high-impact, high-ownership role requiring deep technical expertise and leadership.