Materials Characterization Engineer

We are seeking a Materials Characterization Engineer to provide technical expertise for materials analysis supporting rare-earth permanent magnet R&D and production. As a hands-on individual contributor, you will lead complex investigations, integrate analytical findings into production and R&D plans, and develop reliable testing capabilities in partnership with the laboratory and engineering teams.

About Vulcan Elements

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive, powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Integrity.

Responsibilities

• Define characterization plans that answer engineering questions and support process development, quality investigations, and product qualification.
• Perform and guide characterization within areas of expertise, using optical microscopy, SEM/EDS, ICP-OES, combustion and inert gas fusion analysis, particle sizing, powder rheometry, XRD, or DSC.
• Lead method development, validation, and transfer into routine testing, defining preparation requirements, performance criteria, and documentation.
• Establish calibration and quality-control practices; assess uncertainty, accuracy, and method limitations, and resolve questionable results.
• Review reports, validation studies, and procedures within delegated scope; communicate defensible conclusions and recommendations.
• Develop practical improvements to fixtures, sample handling, and test setups, coordinating specialized repairs or controls work with qualified personnel.
• Promote safe chemical and powder handling, data integrity, and traceability; support audits, technical nonconformance investigations, and corrective actions.
• Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.

Requirements

• B.S. or higher in materials science, materials engineering, metallurgy, chemistry, chemical engineering, or a closely related technical discipline.
• 3+ years of relevant industry experience in materials characterization, metallurgical analysis, analytical chemistry, or materials and processes engineering.
• Demonstrated ability to lead complex investigations, integrate evidence, and develop actionable engineering recommendations.
• Experience developing and validating test methods, evaluating measurement quality, and transferring methods into routine laboratory or production use.
• Strong understanding of composition, microstructure, processing, and property relationships and the limitations of applicable test methods.
• Demonstrated equipment troubleshooting and practical laboratory problem-solving skills, with experience following safe work and quality-system practices.
• Ability to provide technical mentorship, review others' work, and communicate defensible conclusions to technical and non-technical stakeholders.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred

• Deep hands-on expertise in metallurgy and microscopy or elemental analysis, with working knowledge of complementary methods for metallic materials.
• Experience with rare-earth alloys, permanent magnets, powder metallurgy, sintering, or air-sensitive metal powders.
• Proficiency spanning microscopy and analytical chemistry, including SEM/EDS, ICP-OES, LECO/ELTRA analyzers, XRD, powder characterization, or thermal analysis.
• Experience with heat treatment, plating, protective coatings, corrosion evaluation, or fracture analysis.
• Experience commissioning laboratory equipment, designing test fixtures, or improving laboratory workflows during manufacturing scale-up.
• Familiarity with ASTM methods, statistical experimental design, measurement systems analysis, and AS9100 or ISO/IEC 17025 quality systems.

Laboratory Safety and PPE Requirements

• This position requires strict adherence to laboratory safety protocols and regulatory guidelines.
• Employees must consistently wear appropriate personal protective equipment (PPE), including lab coats, safety glasses, gloves, and any additional gear required for specific procedures or chemical handling.
• The role involves working with potentially hazardous materials, equipment, and processes, and team members must follow all established safety rules, maintain a clean and compliant work area, and promptly report any unsafe conditions.
• The individual must be able to complete required training, apply proper safety practices, and demonstrate a strong commitment to maintaining a safe laboratory environment.