Lead Metallurgical Process Engineer – Metallurgy, Heavy Forging

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🕒 May 19

🏛️ District of Columbia – Remote

🏛️ District of Columbia – Remote

💵 $179k - $203k / year

⏰ Full Time

🟠 Senior

👷🏻‍♀️ Engineer

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Westinghouse Electric Company

WebsiteLinkedInAll Job Openings

5001 - 10000 employees

⚡ Energy

Energy • Nuclear • Manufacturing

Westinghouse Electric Company is a leader in the nuclear energy sector, providing innovative solutions and advanced technologies for nuclear power generation. With a strong focus on safety and sustainability, Westinghouse develops and manufactures a range of nuclear components, including pressurized water reactors and small modular reactors. The company also offers extensive training and resource solutions to enhance operational efficiency and support the nuclear industry’s commitment to carbon-free energy.

📋 Description

• Define the process flow for ultra-large forging operations: melting, casting, ingot conditioning, forging sequences, and heat treatment. • Study existing world-class facilities to understand current best practice, and then systematically challenge assumptions about why each process step exists and how it should be executed. • Understand the process steps, parameters, and physical/chemical phenomena that drive homogenization and impurity removal during large ingot casting. • Develop forging process models from first principles: deformation mechanics, thermal profiles, microstructural evolution, and die design for components including reactor pressure vessel shells, steam generator forgings, turbine rotor shafts, and defense applications. • Identify opportunities to fundamentally improve quality, energy consumption, and capital equipment requirements relative to existing global benchmarks. • Collaborate with the project team to produce equipment cost and construction schedule estimates to drive project stage gate deliverables. • Develop the preliminary process design basis document that will feed into detailed engineering for the melting, forging, and heat treatment shops. • Interface with Japanese and allied technical partners to absorb operational knowledge while maintaining an independent, critical perspective on process design.

🎯 Requirements

• Deep understanding of the process steps, parameters, and physical/chemical phenomena that drive homogenization and purity during from stock materials through large ingot casting. • Deep understanding of grain structure formation as a function of heat treatment parameters • Deep understanding of the thermomechanics of open-die forging, including deformation behavior of low-alloy and stainless steels at forging temperatures, grain refinement mechanisms, and the relationship between forging parameters and final mechanical properties. • Experience with large-scale metal forming, heat treatment, or steelmaking processes—ideally in an environment that valued process optimization and cost discipline, not just process execution. • A demonstrated track record of challenging conventional approaches and developing novel process solutions based on fundamental understanding rather than precedent. • Comfort operating as the domain expert on a team of sharp generalists who will constantly ask “why?”—and the intellectual humility to say “I don’t know yet, let’s figure it out.” • 7–15 years of experience. We are specifically looking for someone who has enough depth to be authoritative but has not spent so long in a single paradigm that they cannot see outside it. • Experience in downstream precision machining is a bonus.

🏖️ Benefits

• Competitive compensation packages • 401k with company match • Medical, dental, vision plans • Generous vacation policy, plus holidays