Senior Process Engineer – Alloy Manufacturing
Location: Darlington, SC. Must be a US citizen or permanent resident; no sponsorships offered. Willing to travel between company sites, suppliers, and customers.
Responsibilities
- Manage technical aspects of melting and post‑melting processes, achieving in‑spec chemistry at lowest cost/risk.
- Set chemistry targets aligned with customer and industry mechanical property requirements.
- Control tramp/trace elements in raw materials and recycling streams.
- Verify charge makeup, material suitability, calculation accuracy, and weigh‑up accuracy.
- Control process parameters and consumables for the Horizontal Caster operation.
- Supervise machining of critical components via contractors.
- Maintain and update PLC/HMI software; familiarity with ladder logic.
- Problem‑solve with customers (Foundry and Wrought).
- Educate customers on processes, controls, and capabilities.
- Coordinate customer tours and events.
- Resolve product returns, complaints, and customer concerns.
- Lead continuous scrap and cost reduction initiatives.
- Perform Process and QMS audits of melting, refining, casting, and post‑production operations.
Qualifications
- Intelligent and quick to learn; adapt to evolving environments.
- Bachelor's degree in Metallurgy, Materials Science, or Applied Engineering.
- 3–15 years of experience in metallurgical process engineering.
- Hands‑on, interactive, spending at least 50% of time in plant.
- Leadership and management skills, including: motivation, safety, continuous improvement, cost reduction, and managing technical/non‑technical teams.
- Experience in: basic metals production and refining; quality standards (AS9100, ISO-9002, NADCAP); design and manufacturing of precision machined components; SolidWorks and GD&T; horizontal/vertical continuous casting of Co, Ni, Fe alloys; wrought products, forging, reduction, rolling; data collection, management, and analysis for process control.
Attributes of the Ideal Candidate
- Hands‑on, interactive; minimal 50% plant presence.
- Leadership and management skills across manufacturing.
- Proven cost reduction and cost management.
- Managing technical and non‑technical direct reports.
- Significant experience in all or most of the listed areas.
- Recent graduates may apply.
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