Aerospace Process Engineer - Thermal Spray Coating

Job Summary

We’re looking for a Thermal Spray Process Engineer to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to surface preparation, masking, thermal spray coating application, robotic programming, and process control. Your work will directly impact product quality, performance, turnaround time, delivery, and operational efficiency while helping ensure the reliability of components that support aviation safety worldwide.

Work That Matters

At Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.

Location: Windsor, CT

Travel: Occasional travel required

Schedule: On-site

What You’ll Be Doing

• Develop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.
• Provide day-to-day engineering support to production operations, including monitoring yield, reducing rework, and improving process capability.
• Perform root cause analysis and corrective actions to resolve process and quality issues and prevent recurrence.
• Lead activities that ensure production readiness of thermal spray equipment and associated process technologies.
• Design, develop, and implement tooling, fixtures, gauging, and process improvements that enhance safety, quality, and productivity.
• Program and optimize 6-axis robotic systems used in thermal spray coating applications.
• Develop spray parameters for new coating materials and continuously improve existing coating processes.
• Develop and optimize masking and surface preparation methods, including grit blasting procedures.
• Create and maintain process documentation, including operating procedures, work instructions, process specifications, calibration instructions, training materials, and quality records.
• Support operator training and collaborate with maintenance teams to establish effective preventive maintenance programs.
• Participate in Kaizen, Lean Manufacturing, and continuous improvement initiatives to improve process performance, quality, delivery, and cost.
• Apply Six Sigma and DMAIC methodologies to solve complex manufacturing challenges and drive sustainable process improvements.

What We’re Looking For

• Bachelor’s degree in Engineering or a related science-based discipline such as Materials Science, Chemistry, or Physics.
• 3+ years of engineering experience in a manufacturing environment; aerospace manufacturing, repair, overhaul, or gas turbine experience preferred.
• Experience supporting manufacturing operations, process development, and continuous improvement initiatives.
• Knowledge of root cause analysis, corrective action systems, and statistical problem-solving methodologies.
• Familiarity with Lean Manufacturing principles and structured problem-solving techniques.
• Strong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.

Nice to Have

• Experience with thermal spray equipment and coating process development.
• Experience programming and optimizing 6-axis robotic systems.
• Working knowledge of 3D CAD software such as Siemens NX.
• Knowledge of thermal spray technologies, including:
  • Atmospheric Plasma Spray (APS)
  • Dual Wire Arc Spray
  • Combustion Spray
• Experience with aerospace masking techniques and fixturing design.
• Knowledge of surface preparation requirements, including grit blasting processes.
• Experience supporting aerospace component repair, overhaul, or manufacturing operations.
• Lean Six Sigma Green Belt certification or participation in Kaizen events.
• Familiarity with aerospace quality systems and process control methodologies.

Work Environment & Physical Requirements

• Work is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.
• Regular interaction with production areas, laboratories, and repair operations is required.
• Ability to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.
• Ability to occasionally lift and carry up to 25 pounds.
• Must be able to wear required personal protective equipment (PPE) and comply with all safety policies and procedures.