Senior Coatings Process Engineer (Thermal Spray)

Chromalloy is a global engineering & solutions company. We are a leading provider of aftermarket parts, repairs, and solutions that safely & reliably extend the life of aircraft engines and gas turbines. We develop, manufacture and repair critical turbine components for a range of engine platforms. Our solutions support the engines running the aerospace, energy and defense industries around the world.

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Why work at Chromalloy?

Chromalloy employees are proud, passionate problem-solvers who strive to live our values every day. A career with Chromalloy is an opportunity to learn from top industry experts, work with important technologies, and unlock a passion for innovation. Join our team of experts, innovators and problem-solvers delivering world-class solutions for our customers. As a global company, we are committed to creating an inclusive environment where all employees feel represented, heard, and able to bring their best selves to work every day. Be part of something bigger with Chromalloy!

Our Total Rewards Program is designed to support you today and in the future.

• Comprehensive and flexible benefit options starting on day one, including medical, dental, vision, EAP, wellness incentives, and 401(k) with employer matching.
• Development & progression opportunities for every employee - regular performance conversations, training and development curriculum, and engineering fellowship programs.
• Paid time off, including vacation, sick time, paid holidays, and parental leave-all eligible on your first day of employment!
• Competitive pay, including eligibility for quarterly and annual bonuses, depending on role and site.

Eligibility for individual benefit plans may vary based on employment status.

The Senior Process Engineer serves as the technical leader for overlay coating applications supporting the manufacturing and repair of high-pressure gas turbine components. Reporting to the Engineering Manager, this role is responsible for sustaining, optimizing, and advancing specialized coating processes including EB-PVD (Electron Beam Physical Vapor Deposition) and thermal spray technologies.

This position plays a critical role in ensuring process capability, regulatory compliance, and continuous improvement across coating and related treatment operations. The Senior Process Engineer partners cross-functionally with Operations, Quality, Maintenance, and Product Engineering to deliver safe, repeatable, and cost-effective solutions in a highly regulated aerospace environment.

Due to government regulation only US persons (U.S. citizen, U.S. naturalized citizen, U.S. permanent resident, holder of U.S. approved political asylee or refugee status) may be considered for this role.

Key Responsibilities

• Lead the technical ownership of EB-PVD and thermal spray overlay coating processes for production and repair of gas turbine components.
• Ensure compliance with internal quality systems, customer requirements, and industry standards (e.g., NADCAP, OEM specifications).
• Monitor and analyze process performance metrics (yield, scrap, rework, throughput, cost drivers) and implement corrective actions to improve capability and stability.
• Serve as the primary technical resource for troubleshooting equipment, coating defects, metallurgical issues, and process deviations.
• Drive root cause analysis and corrective/preventive actions using structured problem-solving methodologies (e.g., 8D, RCCA, PFMEA).
• Support capital equipment planning, commissioning, validation, and process qualification for new coating systems or upgrades.
• Lead new product introduction (NPI) and program launches, ensuring robust process readiness, documentation, and training prior to production release.
• Participate in cross-functional design and repair development reviews to ensure manufacturability and process compatibility.
• Author and maintain technical documentation including work instructions, process specifications, validation reports, and training materials.
• Mentor and provide technical guidance to junior engineers and operations personnel.
• Identify and implement cost reduction opportunities related to materials, energy consumption, cycle time, and equipment utilization.
• Support audits (internal, customer, and regulatory) and present technical justifications as required.
• Promote a culture of safety, accountability, and continuous improvement within the engineering and operations teams.

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, or related technical discipline.
• 8+ years of experience in coating manufacturing environments, with direct experience in PVD (Physical Vapor Deposition), thermal spray is preferred.
• Strong understanding of metallurgical principles, turbine component repair processes, and special process controls.
• Demonstrated experience in root cause analysis, process validation, and continuous improvement initiatives.
• Ability to work cross-functionally in a fast-paced, regulated manufacturing environment.
• Strong technical writing and communication skills.
• Experience in CAD software preferred (Siemens NX).
• Experience with vacuum technology a plus.

Due to government regulation only US persons (U.S. citizen, U.S. naturalized citizen, U.S. permanent resident, holder of U.S. approved political asylee or refugee status) may be considered for this role.

Chromalloy participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

Any offer of employment will also be conditioned upon the successful completion of a background investigation and drug screen in accordance with company policy and applicable federal and state regulations.

Chromalloy is an equal opportunity employer - vets/disabled.

In the United States, if you need a reasonable accommodation for the online application process due to a disability, please contact: https://www.chromalloy.com/contact-us/