Overview In this role you will lead advanced computational modeling initiatives to link processing, microstructure, and properties of aluminum products. You will drive ICME, multi-physics and AI-informed modeling, integrating experiments and plant data to optimize casting, rolling, heat treatments and related processes. You'll partner with R&D and plant engineers to accelerate product innovation and manufacturing performance. The work focuses on sustainable product development and process optimization at scale.
Compensation / Benefits- Medical, dental and vision insurance
- Health Savings Account (HSA) and Health Reimbursement Account (HRA)
- Flexible Spending Account (FSA)
- Company-paid life insurance; voluntary life coverage
- Paid vacation and PTO
- 401(k) with company match
Responsibilities- Develop and maintain ICME models connecting process, microstructure and properties for flat aluminum sheet products
- Design multi-scale models linking process parameters with microstructure and properties for casting, rolling, heat treatment, coating, and related processes
- Build constitutive, formability and failure prediction models (flow stress, work hardening, FLD, FLC, earing, spring-back, bendability)
- Create/refine process simulation tools using finite element, finite difference, cellular automata, and phase-field methods
- Integrate modeling with experimental characterization (SEM, EBSD, XRD, DSC) and plant data for validation
- Develop thermodynamic/kinetic models with Thermo-Calc, DICTRA, TC-Prisma, Pandat for alloy design and optimization
- Lead end-to-end modeling projects from scoping to deployment to improve sheet products across markets
- Automate workflows to predict microstructure-property relationships and incorporate plant trial feedback
- Collaborate with plant engineers and R&D teams to troubleshoot and improve productivity, recovery, and quality
- Document methodologies and results; contribute to IP through disclosures and patents
Key requirements- Advanced degree (M.S. or Ph.D.) in Materials Science, Mechanical Engineering, or related field with >10 years in computational modeling
- Expertise in metallurgy and materials science; strong focus on metal systems, especially aluminum alloys; flat rolled aluminum experience preferred
- Proficiency in Thermo-Calc, DICTRA, TC-Prisma, Pandat; experience with finite element, finite difference, cellular automata, phase-field methods
- Programming skills in MATLAB, FORTRAN, C/C++; statistical tools such as JMP and R
- Strong metallurgical principles and characterization techniques; excellent communication and project management skills
- Track record of solving plant issues through modeling with measurable business impact; experience deploying predictive models in production environments
- Strong communication and collaboration
- Problem-solving mindset
- Project management
- Thermo-Calc, DICTRA, TC-Prisma, Pandat
- MATLAB, FORTRAN, C/C++
- Finite element, finite difference, cellular automata, phase-field modeling
