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Failure Analysis Engineer Jobs in Virginia (NOW HIRING)

Northstrat

Senior Reliability Engineer

Sterling, VA · On-site

Conduct root-cause and failure analysis on RF and EW component and board-level failures, working ... Must have 8+ years of reliability engineering experience, including significant work on RF ...

GRVTY

Senior Reliability Engineer

Sterling, VA · On-site

Conduct root-cause and failure analysis on RF and EW component and board-level failures, working ... Mentor junior reliability engineers and help mature the organization's reliability processes and ...

GRVTY

Senior Reliability Engineer

Sterling, VA · On-site

Conduct root-cause and failure analysis on RF and EW component and board-level failures, working ... Mentor junior reliability engineers and help mature the organization's reliability processes and ...

advansix

Sr. Maintenance Engineer

Richmond, VA

$86K - $129K/yr

... failure analyses, equipment, and process improvements and inspection findings · Support site ... engineering or related field · Six Sigma Green Belt certified preferred · 3-5 years of experience ...

advansix

Sr. Maintenance Engineer

Chester, VA · On-site

$86K - $129K/yr

... failure analyses, equipment, and process improvements and inspection findings · Support site ... engineering or related field · Six Sigma Green Belt certified preferred · 3-5 years of experience ...

GRVTY

Senior Reliability Engineer

Sterling, VA

Conduct root-cause and failure analysis on RF and EW component and board-level failures, working ... Mentor junior reliability engineers and help mature the organization's reliability processes and ...

LanceSoft Inc

Reliability Engineer III

Elkton, VA · On-site

$99K - $125K/yr

Through analysis of equipment history, process data, and Failure Modes Effect Analysis, the Reliability Engineer is responsible for the correction of equipment problems causing repetitive failures.

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Failure Analysis Engineer information

See Virginia salary details

$45.1K

$92.4K

$134.3K

How much do failure analysis engineer jobs pay per year?

As of Sep 3, 2026, the average yearly pay for failure analysis engineer in Virginia is $92,380.00, according to ZipRecruiter salary data. Most workers in this role earn between $69,400.00 and $117,000.00 per year, depending on experience, location, and employer.

What does a failure analysis engineer do?

Failure analysis engineers check and identify problems associated with business processes. These errors primarily take place in electrical systems. Failure analysis engineers determine the cause of equipment failure and decide on an action plan to avoid similar issues in the future. Daily responsibilities include conducting tests on electrical systems to determine usability and life cycle, performing preventative maintenance, and conducting emergency maintenance on electrical components. Qualifications typically include a master’s degree in mechanical or electrical engineering, but most employers also provide on-the-job training.

What does a failure analysis engineer do?

A Failure Analysis Engineer investigates the causes of failures in products, components, or systems to determine why they did not perform as expected. They use various analytical techniques such as microscopy, spectroscopy, and stress testing to identify defects or issues. Their work helps manufacturers improve product reliability, prevent future failures, and enhance overall quality. These engineers often collaborate closely with design, manufacturing, and quality assurance teams to implement corrective actions based on their findings.

What are the key skills and qualifications needed to thrive as a failure analysis engineer?

To thrive as a Failure Analysis Engineer, you need a solid background in materials science, electrical or mechanical engineering, and experience with analytical and diagnostic techniques, typically supported by a relevant engineering degree. Familiarity with laboratory tools such as scanning electron microscopes (SEM), X-ray analysis systems, and failure analysis software is common, and certifications like Six Sigma can be beneficial. Strong problem-solving skills, attention to detail, and effective communication are crucial soft skills for clearly documenting findings and collaborating with cross-functional teams. These skills and qualities are essential to accurately identify root causes of failures, drive product improvements, and minimize costly defects in manufacturing processes.

What are some common challenges faced by failure analysis engineers, and how can they be addressed?

Failure Analysis Engineers often encounter challenges such as limited access to failed components, incomplete failure histories, and tight deadlines for root cause identification. Overcoming these challenges requires strong attention to detail, effective communication with cross-functional teams, and creative problem-solving skills. Building a robust process for data collection and collaborating closely with manufacturing, design, and quality teams can help ensure thorough investigations and more accurate recommendations for corrective actions.

What is the difference between Failure Analysis Engineer vs Materials Engineer?

AspectFailure Analysis EngineerMaterials Engineer
Required CredentialsBachelor's or Master's in Engineering, certifications like ASQ CQE or FAIBachelor's or Master's in Materials Science or Engineering, similar certifications
Work EnvironmentLaboratories, manufacturing plants, quality assurance settingsResearch labs, manufacturing facilities, product development
Industry UsageAutomotive, electronics, aerospace, manufacturingMaterials development, testing, quality control across industries

Failure Analysis Engineers focus on diagnosing product failures to improve quality, often working in labs and manufacturing settings. Materials Engineers develop and test materials used in products, ensuring durability and performance. While both roles require similar credentials and work environments, Failure Analysis Engineers specialize in failure diagnostics, whereas Materials Engineers focus on material development and testing.

How much does a failure analysis engineer make?

Failure analysis engineers typically earn a median annual salary between $70,000 and $100,000, depending on experience, location, and industry. Senior roles or those with specialized skills in materials or electronics can earn higher salaries, often exceeding $120,000 annually.
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Failure Analysis Engineer jobs near you
Infographic showing various Failure Analysis Engineer job openings in Virginia as of August 2026, with employment types broken down into 100% Full Time. Highlights an 100% In-person job distribution, with an average salary of $92,380 per year, or $44.4 per hour.

15691-Engineer Material Process 3@ Dulles - Bldg 1-45101 Warp Dr (VA31)

Prolim Global

Dulles, VA • On-site

Contractor

Re-posted 18 days ago

Job description

Description


At Northrop Grumman, we have incredible opportunities to work on revolutionary systems that impact people's lives around the world today, and for generations to come. Our pioneering and inventive spirit has enabled us to be at the forefront of many technological advancements in our nation's history - from the first flight across the Atlantic Ocean, to stealth bombers, to landing on the moon. We look for people who have bold new ideas, courage and a pioneering spirit to join forces to invent the future, and have fun along the way.
Northrop Grumman is looking for a Materials Engineer to support the Reliability Analysis Lab (RAL) in Dulles, Virginia.
Responsibilities:
· Perform failure analysis of materials/hardware to determine the root cause of failure and identify failure modes.
· Perform materials analysis and characterization.
· Perform weld joint analysis.
· Perform materials testing per industry standard specifications and internal requirements.
· Perform inspection of printed wiring board for defects and anomalies.
· Use analytical tools and equipment to inspect and analyze parts, materials, and flight hardware.
Basic Qualifications for Systems Engineer - Integration and Test:
· Bachelor's degree in Materials Engineering. Bachelor’s degree is Physics with some background in materials is acceptable.
· Knowledge and experience with lab equipment, such as, scanning electron microscope, optical microscope, spectroscopy, x-ray equipment.
Preferred Qualifications for Systems Engineer - Integration and Test:
· Familiarity with materials, such as, aluminum, titanium, steel.
· Familiarity with processes, such as, rolling, forging, heat treatment, welding, corrosion.
· Familiarity with industry standard documents, e.g., ASTM, ASM, NASA, MIL.