Materials Engineer, Metals (Starship)

About the role

Our Starship Materials Engineering team is serving as experts in various material disciplines to the broader company and working on making the best rockets and spacecraft in the world. As a member of this team you will constantly improve the materials and processes used to make these structures and components.

This role will primarily be supporting component level hardware including, but not limited to control devices and mechanisms that drive critical capabilities on Starship/Super Heavy - from regulators and butterfly valves to flap/fin actuators.

We design, manufacture, and test valves, regulators, and actuators for maximum reliability in extreme environments, compatibility with various fluids, temperatures ranging from 80 to 800K, and pressures beyond 800 bar.

Special processing of metals including, but not limited to, plate/bar/sheet processing, casting, forging, coatings, and heat treating and expected to make an impact on the design, analysis, and manufacturing of components and mechanisms that spans across all our Starship vehicles. If your goal is to make an impact on the cutting edge of propulsion control devices, materials, and manufacturing technologies, this is the role for you.

Responsibilities

• Design, develop, and deploy materials and process direction for propulsion, mechanism, and valve system designs and manufacturing
• Increase reliability of internal design's manufacturing processes through material and process selection, analysis, development, and test
• Develop physical, mechanical, and thermal properties for materials
• Improve our special processes and materials through characterization and development
• Work directly with component design build and test engineering, design reliability, and production teams on a daily basis
• Perform root cause investigations using fractography, metallography, and testing
• Provide technical reviews and advising for design efforts specifically related to drawings, specifications, and material requirements
• Collaborate with other engineers, subject matter experts, and technicians to solve complex material and processing challenges on our current and next generation vehicles

Basic Qualifications

• Bachelor's degree in materials engineering or other engineering discipline with emphasis on materials
• 2+ years of professional work experience in a materials engineering related role

Preferred Skills and Experience

• Master's degree or PhD in materials engineering or related field
• Experience and expertise with multiple of the following manufacturing methods: tribological coatings (conversion, inorganic, dry-film lubricants), sheet/plate metal processing, casting, forging, brazing, welding, and heat treating
• Tribological processes including, but not limited to evaluating and implementing protective coatings (polyurethane, urethane, conversion coating, inorganic coatings, dry-film lubricants, etc.) for internal and external environmental conditions including thermal, wear, atmospheric, and space environments
• Understanding of mechanical testing methods for metals including wear, tensile, fracture and fatigue and
• Familiarity with development of design allowables
• Experience with failure analysis and fractography including characterization techniques such as Fourier-transform infrared spectroscopy (FTIR), Scanning Electron Microscopy (SEM), and metallographic analysis
• Knowledge of aerospace metals including nickel-based alloys, stainless steels, aluminum alloys, and titanium alloys
• Knowledge of fluid and gas compatibility for various launch vehicle and spacecraft propulsion and fluid systems
• Hands-on experience in a manufacturing environment
• Understanding of non-destructive test methods for fracture and fatigue control
• Maintain working knowledge of regulatory requirements, perform associated required tasks, and complete required documentation per SpaceX specifications and other external specification such as NASA, OSHA, ASTM, NACE, ASME, AWS, ASM, etc.

Additional Requirements

• Extended hours and weekend work may be required to support critical project and mission milestones
• Up to 10% domestic travel is expected

Pay range

Level I: $100,000.00 - $115,000.00/per year

Level II: $110,000.00 - $135,000.00/per year

Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience.

Base salary is just one part of your total rewards package at SpaceX. You may also be eligible for long-term incentives, in the form of company stock or long-term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan.

You will also receive access to comprehensive medical, vision, and dental coverage, access to a 401(k) retirement plan, short and long-term disability insurance, life insurance, paid parental leave, and various other discounts and perks. You may also accrue 3 weeks of paid vacation and will be eligible for 10 or more paid holidays per year.

Employees accrue paid sick leave pursuant to Company policy which satisfies or exceeds the accrual, carryover, and use requirements of the law.

Itar Requirements

• To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.