Senior Process Engineer – Alloy Manufacturing

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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