Materials Characterization Engineer

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.

About the Role

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.

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.

Qualifications

• 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 Skills

• 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.