Lead Metallurgical Process Engineer – Metallurgy, Heavy Forging

This is a fully remote position, open to applicants in District of Columbia.

📋 Description

• Define the workflow for ultra-large forging operations, encompassing melting, casting, ingot conditioning, forging sequences, and heat treatment.

• Analyze existing world-class facilities to grasp current best practices, while systematically challenging assumptions regarding the necessity and execution of each process step.

• Comprehend the process steps, parameters, and physical/chemical phenomena that influence homogenization and impurity removal during the casting of large ingots.

• Create forging process models based on first principles, including deformation mechanics, thermal profiles, microstructural evolution, and die design for components like reactor pressure vessel shells, steam generator forgings, turbine rotor shafts, and defense applications.

• Identify opportunities for substantial improvements in quality, energy consumption, and capital equipment needs compared to existing global benchmarks.

• Collaborate with the project team to generate equipment cost and construction schedule estimates to advance project stage gate deliverables.

• Develop the preliminary process design basis document to guide detailed engineering for melting, forging, and heat treatment facilities.

• Engage with Japanese and allied technical partners to acquire operational knowledge while maintaining an independent, critical perspective on process design.

⛳️ Requirements

• Profound understanding of the process steps, parameters, and physical/chemical phenomena that drive homogenization and purity from stock materials through large ingot casting.

• In-depth knowledge of grain structure formation as influenced by heat treatment parameters.

• Extensive understanding of the thermomechanics of open-die forging, including the deformation behavior of low-alloy and stainless steels at forging temperatures, mechanisms of grain refinement, and the correlation between forging parameters and final mechanical properties.

• Experience in large-scale metal forming, heat treatment, or steelmaking processes—preferably in an environment that prioritizes process optimization and cost discipline over mere process execution.

• A proven history of challenging traditional approaches and formulating innovative process solutions grounded in fundamental understanding rather than precedent.

• Ability to function as the domain expert within a team of insightful generalists who will consistently inquire “why?”—along with the intellectual humility to acknowledge, “I don’t know yet, let’s figure it out.”

• 7–15 years of experience, specifically seeking someone with sufficient depth to be authoritative, yet not so entrenched in a single paradigm as to be unable to see beyond it.

• Experience in downstream precision machining is an advantage.

🏝️ Benefits

• Competitive compensation packages

• 401k with company match

• Medical, dental, vision plans

• Generous vacation policy, plus holidays