Metallurgist / Materials Engineer - Joining and Thermal Processing

About the role

We have an opening for a Metallurgist/Materials Engineer to develop, qualify, and implement metallic joining and thermal processing methods for critical national security components. In this hands-on role, you will contribute to process development and metallurgical characterization while partnering with design, modeling, materials, and production organizations across LLNL and external production agencies.

You will work within an interdisciplinary team to establish process-structure-property relationships in structural alloys, with opportunities to grow into a technical leader in joining and thermal processing. This position is in the Materials Engineering Division (MED) within the Engineering Directorate. This position requires full-time on-site presence due to the nature of the work.

This position will be filled at either level based on knowledge and related experience as assessed by the hiring team. Additional job responsibilities (outlined below) will be assigned if hired at the higher level.

You will Develop, execute, and optimize metallic joining and thermal processing methods in a laboratory environment, including electron-beam and laser welding, vacuum brazing, diffusion bonding, and heat treatment for steels, nickel-base alloys, radioactive alloys, and other structural alloys. Provide metallurgical engineering support for processing, materials selection, and properties investigations.

Participate in the design, setup, and operation of processing and joining systems, including fixture design, parameter development, and troubleshooting. Perform metallurgical characterization and joint evaluation using sample preparation, optical microscopy, scanning electron microscopy (SEM), hardness testing, and mechanical testing, such as tensile and bend testing, to assess quality and performance.

Organize, analyze, and present data from experiments and process-development activities to improve understanding of processing-structure-property relationships. Collaborate with scientists, engineers, technologists, designers, and production partners as part of integrated teams spanning design, analysis, prototyping, and production implementation.

Integrate experimental results with analytical or computational models, such as process models, thermal or stress analyses, and microstructure-evolution tools, to inform process-window development and production workflows.

Travel up to approximately 20% to external production facilities, such as Y-12, Los Alamos National Laboratory, and Kansas City National Security Campus, to observe and support operations, review procedures, and provide feedback to LLNL program-management and design teams. Perform other duties as assigned.

Additional job responsibilities, at the SES.2 level Take technical ownership of specific joining and thermal-processing operations, including requirements definition, specification input, process qualification, and continuous improvement.

Provide technical guidance and informal mentoring to less-experienced staff, technicians, and students in joining and processing development, sample preparation, and metallurgical characterization. Lead or co-lead defined technical tasks or small projects, coordinating across team members and tracking progress against scope, schedule, and quality requirements.

Qualifications & Requirements

Ability to obtain and maintain a U.S. Department of Energy (DOE) Q-level security clearance, which requires U.S. citizenship. Bachelor's degree in metallurgical engineering, materials science and engineering, welding engineering, mechanical engineering, or a closely related field, or an equivalent combination of education and relevant experience.

Relevant experience gained through academic research, laboratory coursework, senior design projects, internships, or professional employment. Experience or training in conducting experiments involving metals processing, joining, or metallurgical characterization, including data collection, analysis, and documentation.

Foundational understanding of the relationships between processing parameters, microstructure, and mechanical properties, along with the ability to assess joint and material quality using microstructural observations and basic mechanical-test data. Experience or training in the microstructural characterization of metallic materials and/or joints, including sample preparation and optical microscopy.

• Familiarity with SEM or other advanced methods is a plus.
• Ability to work effectively on multidisciplinary teams, communicate status and results, and incorporate feedback.
• Effective verbal and written communication skills for preparing, presenting, and explaining technical information.
• Commitment to safe work practices and the ability to adapt to evolving priorities.

Ability to travel to external production facilities to support program operations. Additional qualifications at the SES.2 level Working knowledge and relevant experience focused on metallic joining or thermal processing, or in closely related roles.

Experience developing, optimizing, or qualifying joining and processing methods, such as high-energy-density welding, vacuum brazing, diffusion bonding, or hot isostatic pressing (HIP), in a laboratory or production setting. Experience working in quality-controlled or regulated environments, such as DOE, aerospace, or nuclear environments, including the use of procedures, travelers, or work instructions.

Ability to independently plan and execute joining and processing experiments and metallurgical characterization, interpret results, and recommend process or heat-treatment improvements. Experience using, interpreting, or collaborating with analytical or computational models to guide process-development and qualification decisions.

Experience demonstrating increasing technical leadership, such as leading small project efforts, coordinating cross-functional activities, or serving as a technical point of contact.

Pay and benefits

We Desire Degree in welding engineering, or focused coursework, research, or practical experience in welding metallurgy and joining. Master's degree in metallurgical engineering, materials science and engineering, welding engineering, or a closely related field.

Experience operating or developing one or more joining or thermal-processing methods, such as electron-beam or laser welding, vacuum brazing, diffusion bonding, HIP, and complex heat treatments for structural alloys. Experience applying advanced characterization techniques, such as SEM, electron backscatter diffraction (EBSD), and X-ray-based methods, to evaluate joint microstructures and defects.

Understanding of the basic principles of high-performance joining equipment, including system maintenance and troubleshooting. Knowledge of advanced mechanical-testing methods, such as fracture or fatigue testing, and experience joining specialty or hazardous materials in controlled environments, including associated thermal processing.

Familiarity with process-modeling tools, digital workflows, or data-management approaches that support systematic process development and qualification.

Pay Range $121,830 - $185,544 Annually $121,830 - $154,500 Annually for the SES.1 level $146,340 - $185,544 Annually for the SES.2 level This is the lowest to highest salary we in good faith believe we would pay for this role at the time of this posting; pay will not be below any applicable local minimum wage.

An employee's position within the salary range will be based on several factors including, but not limited to, specific competencies, relevant education, qualifications, certifications, experience, skills, seniority, geographic location, performance, and business or organizational needs.

Additional Information

#LI-Onsite Position Information This is a Career Indefinite position, open to Lab employees and external candidates. Why Lawrence Livermore National Laboratory? Included in 2026 Best Places to Work by Glassdoor! If you are selected, we will initiate a Federal background investigation to determine if you meet eligibility requirements for access to classified information or matter.

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