Metallurgical Process Engineer

Company Overview Wellman Dynamics is a leading magnesium and aluminum sand casting foundry specializing in large, dimensionally complex components for aerospace and defense applications, including rotary-wing, aeroengine, and munitions platforms. The company is a portfolio company of J.F. Lehman & Company, a leading aerospace and defense focused private equity firm and is investing in the expansion of its Engineering function to strengthen technical depth, tighten process control, and prepare the business for automation and advanced manufacturing investments. Position Summary At Wellman Dynamics, the Metallurgical Process Engineer manages and improves melting processes for aluminum and magnesium alloys used in aerospace and defense castings. This role ensures that metals meet required chemical and physical specifications before pouring while supporting process control, quality, production efficiency, and compliance with customer requirements.

The Metallurgical Process Engineer conducts metallurgical investigations, develops melting techniques, improves testing parameters, supports furnace and ladle maintenance, and prepares technical documentation for process changes. The role also provides technical guidance to production teams, supports employee training, and drives continuous improvement throughout the Melt Department.

Key Responsibilities

• Manage and lead melting processes to support production requirements and quality objectives.
• Ensure aluminum and magnesium metals meet chemical and physical specifications before pouring.
• Conduct metallurgical investigations and analyses to determine effective melting practices.
• Develop, improve, and implement melting techniques and processes for aluminum and magnesium alloys.
• Research and evaluate equipment, materials, and processing methods to improve melting performance.
• Collaborate with Production, Engineering, Quality, and management on new and improved methods and materials.
• Develop and implement testing parameters for aluminum and magnesium alloys.
• Prepare technical reports and supporting documentation for process changes.
• Maintain current knowledge of industry developments and melting technologies.
• Support furnace and ladle maintenance activities, including inspection of lining repairs.
• Monitor material, machinery, and process quality to meet internal and customer requirements.
• Identify and implement corrective actions and modifications to materials, methods, and equipment.
• Coordinate materials and equipment with supervisors and department managers to support on-time, on-cost, and on-spec production.
• Support inventory accuracy, dross-loss reduction, first-time sample approval, and digital recordkeeping goals.
• Promote safety, housekeeping, positive employee relations, and adherence to company procedures.
• Assist with employee training related to product changes, safety programs, work methods, and departmental expectations.
• Develop innovative approaches to improve productivity and support gain-sharing initiatives.
• Use critical-thinking skills to evaluate process results, identify failures, and implement improvements.
• Perform additional duties as assigned.

Required Qualifications & Experience

• Bachelor’s degree in Metallurgical Engineering, Materials Science, or a related field; equivalent experience may be considered.
• Minimum five years of manufacturing experience; foundry experience preferred.
• Experience with aluminum and/or magnesium melting preferred.
• Knowledge of metallurgical principles, alloy chemistry, melting processes, and material specifications.
• Ability to investigate process issues and determine effective corrective actions.
• Ability to develop and improve technical processes, testing parameters, and work methods.
• Ability to interpret technical requirements and communicate effectively with Production, Engineering, Quality, and management.
• Ability to prepare technical reports and maintain accurate process documentation.
• Ability to support furnace and ladle maintenance and evaluate lining conditions.
• Ability to train employees and promote consistent adherence to melting processes.
• Strong problem-solving, critical-thinking, organizational, and communication skills.
• Ability to work safely in a foundry environment and pass a pre-employment physical.

Preferred Qualifications

• Experience with aluminum and magnesium alloy melting in an aerospace or foundry environment.
• Experience with aerospace customer specifications and quality requirements.
• Familiarity with furnace operation, ladle maintenance, dross control, and metal testing.
• Experience with process improvement, corrective action, and digital production records.
• Experience preparing technical reports, process documentation, or engineering papers.
• Familiarity with inventory control, material planning, and production scheduling.
• Demonstrated willingness to remain current with industry developments and emerging melting technologies.

Success Factors

• Experience with aluminum and magnesium alloy melting in an aerospace or foundry environment.
• Experience with aerospace customer specifications and quality requirements.
• Familiarity with furnace operation, ladle maintenance, dross control, and metal testing.
• Experience with process improvement, corrective action, and digital production records.
• Experience preparing technical reports, process documentation, or engineering papers.
• Familiarity with inventory control, material planning, and production scheduling.
• Demonstrated willingness to remain current with industry developments and emerging melting technologies.