Process Engineer - Metallurgy

Overview

Morgan Advanced Materials is a world leader in advanced materials science and engineering of ceramics, carbon and composites. We operate in a series of well-defined markets where our applications expertise offers our customers a valuable differentiator, engineering high-specification materials, components and sub-assembly parts that solve their challenging technical problems.

The Technical Ceramics business of Morgan Advanced Materials engineers high performance functional and structural ceramic materials, components and sub-assemblies to address customer-specific technical challenges.

The business employs advanced materials science and applications expertise to produce parts that enhance reliability or improve the performance of its customers’ products. Much of what the global business unit makes is used in demanding, harsh or critical environments. Our Technical Ceramics business works in selected segments of the electronics, energy, healthcare, industrial, petrochemicals, security and transport markets, typically in close collaborative customer relationships.

Group Key Figures: Revenue £950m (2021), ~7,500 employees, manufacturing in 30+ countries, and customers in 100+ countries. A UK PLC with head office located in Windsor, Berkshire UK.  Listed on London Stock Exchange; Member of the FTSE 250 Index.

Responsibilities

Process Engineer

Hayward, California 

Morgan Advanced Materials-Technical Ceramics 

Salary: $110,000 - $140,000 DOE + up to 20% annual bonus

Are you a hands-on engineer with experience in metals processing, manufacturing optimization, and continuous improvement? Morgan Advanced Materials is seeking a Process Engineer to support and improve our metal casting, forming, and brazing operations. This is a high-impact role that combines technical expertise, data-driven problem solving, and direct involvement on the manufacturing floor to drive operational excellence and product quality.

As a key member of our engineering team, you will collaborate closely with Production, Quality, R&D, and Supply Chain partners to improve manufacturing performance, troubleshoot process issues, and implement sustainable improvements across operations.

What You'll Do

• Lead troubleshooting and process improvement initiatives for metal casting and metal forming operations.
• Design and execute experiments (DOE) to optimize manufacturing processes, improve yields, and reduce variation.
• Support and develop brazing operations for finished assemblies.
• Monitor process performance, quality metrics, and production yields while utilizing data to identify root causes and implement corrective actions.
• Perform root cause investigations, defect analysis, and process failure evaluations.
• Conduct compositional analysis, mechanical testing, and microstructure evaluations to improve process stability and product quality.
• Develop and maintain standard operating procedures (SOPs), process flows, and manufacturing documentation.
• Apply Statistical Process Control (SPC) techniques to monitor and improve process capability.
• Provide technical guidance related to materials processing, thermodynamics, mechanical properties, and manufacturing methods.
• Partner with R&D, Production, Quality, and Supply Chain teams to support business objectives and new product introductions.
• Support operators and technicians through training, coaching, and technical leadership.
• Drive Lean Manufacturing, Six Sigma, and Kaizen initiatives focused on safety, productivity, quality, and cost reduction.
• Manage multiple engineering projects simultaneously while maintaining timelines and deliverables.

Qualifications

What We're Looking For

Required Qualifications

• Bachelor's or Master's degree in Materials Science, Metallurgical Engineering, or a related engineering discipline.
• Strong understanding of metallurgical processing, manufacturing systems, and materials characterization.
• Experience applying Design of Experiments (DOE) and Statistical Process Control (SPC).
• Strong analytical and problem-solving abilities with experience conducting root cause analysis and implementing corrective actions.
• Excellent communication and presentation skills with the ability to explain technical concepts to diverse audiences.
• Ability to thrive in a fast-paced manufacturing environment while managing multiple priorities and deadlines.
• Strong organizational and project management skills.

Preferred Qualifications

• Experience with metal alloy forming, casting, and processing.
• Hands-on manufacturing engineering experience supporting production operations.
• Knowledge of brazing processes and assembly methods.
• Lean Manufacturing, Six Sigma, or Continuous Improvement experience.

Why Join Morgan Advanced Materials?

Morgan Advanced Materials is a global leader in advanced materials science and engineering, providing innovative ceramic, carbon, and composite solutions that help customers solve complex technical challenges across a wide range of industries.

Our Benefits Include

• Benefits effective on your first day of regular full-time employment
• Medical, Dental, and Vision coverage
• 401(k) retirement savings plan
• Paid vacation, holidays, and sick time
• Annual bonus opportunity of up to 20%

Work Authorization Requirement

This position is subject to U.S. export control regulations. Candidates must be:

• A U.S. Citizen, or
• A Permanent Resident Alien of the United States, or
• A Protected Individual as defined by 8 U.S.C. 1324b(a)(3) and 22 CFR 120.15

Join Morgan Advanced Materials and help shape the future of advanced manufacturing through innovation, process excellence, and materials expertise.

Morgan Advanced Materials is an EEO/AA/M/W/D/V Employer Ind-1