Materials and Process Engineer III – Friction Stir Welding

Application close date: Applications will be accepted on an ongoing basis until the requisition is closed. At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!    This role supports the development and operations of New Glenn, a single-configuration, heavy-lift orbital launch vehicle capable of routinely carrying people and payloads to low-Earth orbit, geostationary transfer orbit, cislunar, and beyond. Its first stage is fully reusable, and the vehicle was designed from the beginning to be human-capable. Job Profile: Materials and Process Engineer III – Friction Stir Welding At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!   This role is part of Blue Origin Upper Stage Development team, which is comprised diverse team of collaborators, doers, and problem-solvers who are relentlessly committed to a culture of safety. We are looking for someone to apply their technical expertise, leadership skills, and commitment to quality to positively impact safe human spaceflight. Passion for our mission and vision is required! Responsibilities include but are not limited to: Lead process qualification, development, documentation, and internal/external readiness reviews Oversee metallographic and mechanical testing of welds and weld samples, and evaluation of materials characterization data or NDT results Evaluate weld defects and recommend improvement plans or repair procedures Work with cross-functional teams that are responsible for selecting materials, manufacturing processes, and suppliers to produce world class aerospace hardware Work hand in hand with quality assurance/engineering for rapid disposition and documentation of non-conformances for tank structure defects Travel as needed for reviews, training, and other tank production support activities Define and write material test plans for design value generation, execute sourcing of testing, and evaluate test data to develop statistics-based design values Support production welding of full scale, cryogenic tanks. Lead development/optimization of FSW processes to meet specification requirements. Troubleshoot weld tool equipment as required. Work closely with tank production teams to ensure that floor support is provided in a timely manner and weld qualification deliverables are met in accordance with the overall launch schedule Minimum Qualifications: B.S. degree or higher in materials engineering, welding engineering, mechanical engineering or related field 6+ years of experience (4+ with relevant M.S.) in the field of metallurgy, with deep knowledge of the interplay between composition, process, microstructure & properties in aerospace materials (preferably in Aluminum alloys) 5+ years of experience with definition & qualification of welding processes (fusion and/or solid state) Experience developing and executing plans for material characterization, such as mechanical testing, environmental testing, and material compatibility analysis Experience supporting design and manufacturing teams in an aerospace environment, including preparing specifications, test reports, and design substantiation documentation Experience interacting with aerospace suppliers, including on-site engineering audits, supplier qualifications and statistical process controls Strong interpersonal and organizational skills with the ability to prioritize and handle small and large projects with a diversity of internal and external customers Ability to earn trust, maintain positive and professional relationships, and contribute to a culture of inclusion Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum Desired Expertise in friction stir welding of aluminum and/or aluminum-lithium alloys for aerospace applications Past experience as an aerospace Materials & Processes engineer Proven experience with sourcing, analyzing, manufacturing, and testing of aerospace grade materials such as aluminums, nickel alloys, titanium, stainless steel and other exotic alloys Working knowledge in basic statistical analysis to generate design allowables Knowledge of material behavior and compatibility in cryogenic tank systems Track record in developing engineering requirements and work instruction documents Culture Statement Don’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles. Export Control Regulations Applicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum. Background Check Required for all positions: Blue’s Standard Background Check Required for Certain Job Profiles:  Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installation Required for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVW