Mechanical Engineer 2 - Power Systems Materials Manufacturing

Mechanical Engineer 2 - Power Systems Materials Manufacturing Responsibilities Our expert staff provide multi-disciplinary solutions to complex energy and environmental issues. Key capabilities include science (chemical and mechanical). We employ a systems perspective that includes discovery technology development and scale-up, as well as economic, regulatory, and market acceptance issues necessary for successful technology commercialization. The Energy Processes & Materials (EP&M) Division focuses on three mission contributions at PNNL: Energy Resiliency, Electricity Infrastructure, & Energy Efficiency and Renewable Energy. The Applied Materials and Manufacturing (AMM) Group in EP&M Division at PNNL is seeking a Mechanical Engineer to lead experimental process development for power systems materials such as conductors and magnets. The position will develop operating conditions and process envelopes for power system materials with enhanced performance enabled by advanced manufacturing platforms such as shear/friction extrusion, friction stir welding/forging, friction stir additive manufacturing and cold spray. The engineer will collaborate with process engineers, manufacturing experts and materials researchers to translate experimental findings into documented operating recommendations based on material. The successful candidate will build a technical specialization in thermomechanical process development and contribute to research planning and publications. Key Responsibilities: • Design experiments to evaluate operating parameters, tooling designs, manufacturing configurations and feedstock conditions using statistical experimental design where appropriate. • Design tooling using CAD and coordinate their development with external or internal manufacturing facilities/vendors. • Investigate process stability, and product quality to develop frameworks for operational controls. • Develop process windows and document the evidence, limitations, and repeatability supporting recommended conditions. • Work with process engineers to design and deploy digital twin technologies that integrate physics-based models, real-time operational data, and advanced analytics to improve manufacturing performance and resilience. • Communicate results through technical summaries, project reports, conference presentations, journal articles and other technical manuscripts. Qualifications Minimum Qualifications: • BS/BA and 2 years of relevant experience -OR- • MS/MA -OR- • PhD • Relevant experience includes friction stir welding, metal extrusion, metal drawing, rolling, friction extrusion, or related solid-phase processing technologies • Experience with mechanical design, tooling design and CAD. Preferred Qualifications: • Research experience in experimental manufacturing, metal forming, or thermomechanical processing, with particular experience with shear-assisted process extrusion. • Experience planning controlled experiments and analyzing quantitative process and materials data. • Familiarity with instrumentation, process data acquisition, and evaluation of experimental uncertainty. • Ability to document technical findings and collaborate across engineering, materials science, and operations. • Experience with mechanical design, tooling design and CAD. • Hands-on experience commissioning or developing processes on research or pilot equipment. • Publications or demonstrated research contributions in manufacturing process development. • Developing interns, post bachelor's, post masters, and post doctorates. Hazardous Working Conditions/Environment Not Applicable Testing Designated Position This is not a Testing Designated Position (TDP). Rockstar Rewards Employees and their families are offered medical insurance, dental insurance, vision insurance, robust telehealth care options, several mental health benefits, free wellness coaching, health savings account, flexible spending accounts, basic life insurance, disability insurance*, employee assistance program, business travel insurance, tuition assistance, relocation, backup childcare, legal benefits, supplemental parental bonding leave, surrogacy and adoption assistance, and fertility support. Employees are automatically enrolled in our company-funded pension plan* and may enroll in our 401 (k) savings plan with company match*. Employees may accrue up to 120 vacation hours per year and may receive ten paid holidays per year. * Research Associates excluded. **All benefits are dependent upon eligibility. Click Here For Rockstar Rewards Notice to Applicants PNNL lists the full pay range for the position in the job posting. Starting pay is calculated from the minimum of the pay range and actual placement in the range is determined based on an individual's relevant job-related skills, qualifications, and experience. This approach is applicable to all positions, with the exception of positions governed by collective bargaining agreements and certain limited-term positions which have specific pay rules. As part of our commitment to fair compensation practices, we do not ask for or consider current or past salaries in making compensation offers at hire. Instead, our compensation offers are determined by the specific requirements of the position, prevailing market trends, applicable collective bargaining agreements, pay equity for the position type, and individual qualifications and skills relevant to the performance of the position. Minimum Salary USD $89,300.00/Yr. Maximum Salary USD $131,200.00/Yr.