Sr. Engineer, Process Modeling in New Kensington, PA at Arconic

Date Posted: 5/3/2018

Job Snapshot

Job Description

  • Be a process modeling resource in the area of mechanics, linear and non-linear materials, thermal transient analysis, and in complex multi-disciplinary thermo-mechanical processes
  • Conduct analysis of metal forming processes and provide solutions using stress and microstructural computational analysis
  • Integrate modeling and data analytics knowledge to facilitate the deployment of digital solutions (i.e. digital thread/twins) in manufacturing processes such as additive manufacturing
  • Apply expertise to link thermo-mechanical processing to microstructure and properties
  • Support Integrated Computational Materials Engineering efforts to speed up materials, process and product development
  • Leverage data and process modeling for integrated controls to establish real time decision making
  • Apply process modeling to solve problems of importance to Arconic and its customers in a broad range of markets including aerospace, automotive and defense and other new and existing markets.
  • Support process improvement and development efforts in hot and cold bulk forming technologies such as extrusion, rolling, forging, stretching, rod and tube forming, among others
  • Conduct applied or advanced process modeling to reduce process cycle times, gain better insights into critical design parameters to increase Arconic’s competitive advantage.
  • Support efforts in designing, modifying, improving manufacturing processes in a broad range of markets including aerospace, automotive and defense, and other new and existing markets.
  • Perform applied engineering and advanced computational analysis, in addition to lab-scale and plant-scale studies to develop solutions to complex thermo-mechanical problems.
  • Participate in the execution of multi-disciplinary R&D projects in the area of process modeling and thermo-mechanical processing
Major Activities / Key Challenges:
  • Conduct Process Modeling using engineering or other simplified models or more advanced models such as Finite Element or Cellular Automaton (CA) for microstructure analysis
  • Conduct multi-length scale modeling of processes and micro-structure or grain structure evolutions
  • Conduct analysis of metal solidification processes to assess shrinkage porosity, grain structure, micro and macro porosity, surface and internal cracks and inclusions
  • Develop models or tools that make use of image data or micrographs to correlate the microstructure with composition and product mechanical properties (fatigue, fracture toughness, etc.)
  • Propose machine learning algorithms from image data analysis to identify and quantify surface defects, microstructural inhomogeneities, pores and pore formation mechanisms during manufacturing processes
  • Use ICME (Integrated Computational Materials Engineering) to link process-structure-property of various alloys
  • Support efforts in Digital and Smart Manufacturing initiatives by developing digital solutions to automate Arconic’s processes
  • Work within a multi-disciplinary team to establish a protocol for materials development (process-microstructure-properties) that when combined with data analytics, machine learning and artificial intelligence can accelerate the development of commercially relevant materials
  • Apply process modeling expertise in the development of manufacturing practices and strategies to support process and product development in new and existing markets
  • Develop and implement specialized user subroutines (i.e. for heat transfer, contact or materials or microstructure applications) into commercially available FE software codes
  • Provide technical support to process development, product and materials engineers, and Arconic customers
  • Support technical collaborations with outside researchers, universities and national labs in order to leverage Arconic resources
  • Collaborate with other engineers to develop process modeling related projects; help identify needs and recommend project approaches
  • Foster collaborative relationships with ATC personnel and external resources such as consultants, technology suppliers, and other technology organizations.
  • Identify and develop creative and innovative solutions to problems of a conceptual nature, and/or develop new technology through exploration and synthesis of ideas, concepts and existing technology.
  • Monitor the technical environment and identify new process and simulation techniques of interest to Arconic.
  • Conduct literature surveys and exploratory research.
Essential Knowledge & Skills / Education:
  • Working knowledge of manufacturing processes used for metal or materials processing
  • Expertise in multi-disciplinary and multi length scale computational approaches used to model thermo-mechanical processes and materials micro-structure
  • Knowledge of key Process Modeling Computational and Data Analytics tools
  • Ability to work collaboratively across a broad spectrum of internal and external customers and resources
  • Ability to conduct sophisticated lab-scale experiments
  • Strong technical writing and presentation skills

Basic Qualifications

  • Master of Science degree in Mechanical, Civil, or Structural Engineering; Computational Materials Science; Engineering Mechanics or Aerospace; or Materials Science or Engineering from an accredited institution
  • Minimum 2 years graduate level experience in programming (C, C++, Fortran, Matlab)
  • Minimum 2 years graduate level experience in finite element software (i.e. DEFORM, ABAQUS, COMSOL, PRO-CAST) and CAE software tools (NX, SolidWorks, Autocad)
  • Minimum 2 years graduate level experience in modeling of metals deformation or materials processes
  • Employees must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire. Visa sponsorship is not available for this position.
  • This position is subject to the International Traffic in Arms Regulations (ITAR) which requires U.S. person status. ITAR defines U.S. person as an U.S. Citizen, U.S. Permanent Resident (i.e. 'Green Card Holder'), Political Asylee, or Refugee.

Preferred Qualifications

  • PhD degree in Mechanical Engineering, Computational Materials Science, Engineering Mechanics or Aerospace from an accredited institution
  • 2 years experience in modeling of metals deformation or materials processes in an industrial setting
  • 2 years experience in programming (C, C++, Fortran, MATLAB, Python)
  • 2 years experience in finite element software (i.e. DEFORM; ABAQUS standard/Explicit: User-Defined subroutines, UMAT, VUMAT; COMSOL, PROCAST/CA)
  • 2 years experience in Computer Aided Design (i.e. NX, SolidWorks, Autocad)
  • 2 years experience in statistical and optimization or machine learning software (i.e. JUMP, R Statistical software, ISIGHT)
  • Strong background in engineering principles of material deformation, metals deformation, heat transfer, solidification as related to metal processing operations; fracture mechanics, and plasticity
  • Solid expertise and knowledge in non-linear material modeling, linear and non-linear Finite Element Analysis; Crystal plasticity, Constitutive material modeling and multi-physics modeling
  • Solid Knowledge of ICME (Integrated Computational Materials Engineering) principles and computational tools to link process-structure-property
  • Capability to integrate modeling and data analytics knowledge to facilitate the deployment of digital solutions in manufacturing processes
  • Experience with data and process modeling integration for controls applications to establish real time decision making
  • Capability to develop models or tools that make use of image data or micrographs to correlate the microstructure with mechanical properties
  • Expertise in conducting Macro and Micro FE modeling or at various length scales in Thermo-Mechanical processing
  • Experience with the development of aluminum or other alloy constitutive models and their implementation in FE codes
  • Experience in planning and conducting experiments and interpreting the resultant data.
  • Experience in process model development for applications of industrial processes.
  • Ability to clearly communicate both technical and business aspects of R&D projects.
  • Critical Thinking - Ability to analyze problems, define key parameters, and propose and implement effective solutions.