Lead Engineer - Coatings Lab Specialist

Job Description Summary

The Lead Engineer - Coatings Lab Specialist will perform designated tasks and duties within the Engineering Testing Labs, focusing on the Spray Lab Operations. The role requires strict adherence to lab processes, procedures, and safety protocols. The individual will be responsible for developing, optimizing, and executing thermal spray coating processes (Plasma Spray, HVOF, Cold Spray) for advanced materials and components. This position involves leading technical projects, ensuring coating quality, supporting R&D initiatives, and collaborating with cross functional teams to meet performance and reliability targets.

Job Description

Roles and Responsibilities

Technical Expertise

• Operate and maintain HVOF, Plasma and Cold spray systems
• Perform coating characterization (microstructure, adhesion, hardness, porosity, wear/corrosion resistance).
• Apply industry standards (ASTM, ISO, AMS) in coatings.
• Operate spray robots and adhere to developed test procedures.
• Identify opportunities for process improvements.
• Implement innovative solutions to enhance efficiency and output.

• Oversee daily operations of the spray coating laboratory, ensuring safe and efficient execution.
• Manage project timelines and deliverables.
• Lead lab technicians and mentor junior engineers.
• Drive coating projects from concept through qualification.
• Inventory management
• Ensure calibration and maintenance of laboratory equipment.
• Coordinate with vendors for servicing and repairs.
• Mentor laboratory staff in equipment operation and maintenance.
• Identify skill gaps and recommend training programs.

• Maintain a safe working environment in line with health and safety regulations.
• Handle hydrogen gas safely and comply with flammable environment testing standards.
• Apply safety protocols for handling high-temperature processes, gases, and powders.
• Manage gas bank maintenance and labeling per GHS standards.
• Conduct regular safety audits and implement corrective measures.
• Proactive identification of safety risks and countermeasures.

• Follow quality control procedures to maintain high standards in coating processes.
• Ensure adherence to safe operating procedures by all team members.
• Monitor and evaluate test results for accuracy and reliability.
• Maintain thorough documentation and records.

• Maintain detailed records of procedures, results, and safety incidents.
• Prepare and present technical reports to management and stakeholders.

• Collaborate with cross-functional teams to support R&D projects.
• Communicate effectively with stakeholders on lab capabilities and results.
• Participate in reviews with senior leaders, customers, and stakeholders.

• Graduate degree or diploma in Materials, Mechanical, Mechatronics, or related engineering discipline.
• Minimum 8 years of relevant experience in thermal spray coatings.
• Knowledge of industrial safety processes (fire, chemical, electrical, compressed gases, LOTO).
• Hands-on experience with thermal spray systems, calibrations, powder feeders, and spray guns.
• Proficiency in Microsoft Office (Word, Excel, PowerPoint, Outlook, Teams).
• Ability to interpret engineering drawings (Unigraphics, AutoCAD).
• Basic understanding of PLC, controls, and processes.
• Willingness to work in shifts and travel (~10% domestic/international).
• Ability to collaborate with design, manufacturing, and quality teams.

• Master's or PhD in Materials Science, Mechanical Engineering, or related field.
• Experience with advanced coatings (ceramic, carbide, metallic alloys, bond coats).
• Knowledge of thermal barrier coatings (TBCs) and functional coatings for aerospace, energy, or automotive applications.
• Familiarity with advanced characterization techniques (SEM/EDS, XRD, thermal conductivity, residual stress analysis).
• Experience with automation, robotics, or digital monitoring in thermal spray systems.
• Proficiency with Six Sigma and other quality tools.
• Relevant professional certifications (ASM Thermal Spray Society, NACE, AWS).

• To comply with US immigration and other legal requirements, it is necessary to specify the minimum number of years' experience required for any role based within the USA. For roles outside of the USA, to ensure compliance with applicable legislation, the JDs should focus on the substantive level of experience required for the role and a minimum number of years should NOT be used.