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Failure Analysis Engineer Jobs in Wisconsin (NOW HIRING)

Amtec Corporation

Manufacturing Engineer

Janesville, WI · On-site

$67K - $86K/yr

Engineering REPORTS TO: Manufacturing Engineering Manager POSITION SUMMARY : Provides technical ... Create / Lead Failure Mode and Effects Analysis (FMEA) for assigned programs. 14. Support customer ...

Milwaukee Tool

Reliability Engineer II

Milwaukee, WI

$101K - $127K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in electrical or mechanical engineering or ...

Milwaukee Tool

Reliability Engineer II

Milwaukee, WI · On-site

$101K - $127K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in electrical or mechanical engineering or ...

Milwaukee Tool

Reliability Engineer II

Brookfield, WI · On-site

$97K - $122K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in Electrical or Mechanical Engineering or ...

Milwaukee Tool

Reliability Engineer II

Brookfield, WI

$97K - $122K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in Electrical or Mechanical Engineering or ...

Milwaukee Tool

Reliability Engineer II

Milwaukee, WI

$101K - $127K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in electrical or mechanical engineering or ...

Milwaukee Tool

Reliability Engineer II

Milwaukee, WI · On-site

$101K - $127K/yr

Ensure timely failure reporting and drive root cause analysis and effective corrective/preventative actions (FRACA) Job Requirements * Bachelor's Degree in electrical or mechanical engineering or ...

Judge Group, Inc.

Controls Engineer

Pewaukee, WI · On-site

$97K - $143K/yr

Perform root cause analysis and failure investigations, implementing corrective and preventive ... Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, or ...

GAF Materials Corp.

WI · On-site

$90 - $130/hr

Knowledge: Preference toward Mechanical Engineering with knowledge of maintenance & reliability ... Using root cause failure analysis techniques, plus through oversight of the FRACAS Team, implements ...

New

Cenovus Energy, Inc.

Electrical Engineer

Superior, WI · On-site

The Electrical Reliability Engineer is responsible for ensuring the reliability and performance of ... Perform root cause failure analysis (RCFA) for electrical equipment failures that meet defined ...

SiFive, Inc.

WI · On-site

$140 - $210/hr

## Staff Design Verification Engineer - High Performance CPU CoreApplylocations: Austin, Texas, United ... Drive efficient failure analysis and root-cause debug across specification, RTL, test content, and ...

New

Cenovus

Electrical Engineer

Superior, WI · On-site

The Electrical Reliability Engineer is responsible for ensuring the reliability and performance of ... Perform root cause failure analysis (RCFA) for electrical equipment failures that meet defined ...

Donan

Forensic Engineer Contractor

Milwaukee, WI

Two plus years of experience in failure analysis, and knowledge of residential and construction ... Forensic Engineer, Civil Engineer, Design Engineer, Structural Engineer, Construction Management ...

Donan

Forensic Engineer Contractor

Milwaukee, WI · On-site

Two plus years of experience in failure analysis, and knowledge of residential and construction ... Forensic Engineer, Civil Engineer, Design Engineer, Structural Engineer, Construction Management ...

ABB

Quality & Reliability Engineer

New Berlin, WI · On-site

$100K - $126K/yr

Product Engineering & Quality Manager The Quality & Reliability Engineer plays a critical role at ... Demonstrated experience in field troubleshooting, failure analysis, or quality investigation of ...

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Showing results 41-60

All JobsFailure Analysis Engineer JobsFailure Analysis Engineer Jobs in Wisconsin

Failure Analysis Engineer information

See Wisconsin salary details

$45.9K

$94.1K

$136.8K

How much do failure analysis engineer jobs pay per year?

As of Aug 7, 2026, the average yearly pay for failure analysis engineer in Wisconsin is $94,051.00, according to ZipRecruiter salary data. Most workers in this role earn between $70,700.00 and $119,100.00 per year, depending on experience, location, and employer.

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, education, and location. Entry-level positions may start lower, while experienced engineers with specialized skills or certifications can earn higher salaries, especially in industries like aerospace, electronics, or manufacturing.

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.

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 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 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 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.
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What are popular job titles related to Failure Analysis Engineer jobs in WI? For Failure Analysis Engineer jobs in WI, the most frequently searched job titles are:
Failure Analysis Engineer jobs near you
Infographic showing various Failure Analysis Engineer job openings in Wisconsin as of August 2026, with employment types broken down into 88% Full Time, 6% Part Time, and 6% Contract. Highlights an 100% In-person job distribution, with an average salary of $94,051 per year, or $45.2 per hour.

Sr Engineer Materials - Aluminum Systems

Harley-Davidson

Wauwatosa, WI • On-site

$101K - $139K/yr

Full-time, Part-time

Medical, Retirement

Re-posted 5 days ago

Job description

Auto req ID: 54007 
Title: Sr Engineer Materials - Aluminum Systems 
Job Function: Engineering 
Location: PDC
Workplace Category:Onsite 
Company: Harley-Davidson Motor Company 
Full or Part-Time: Full Time 
Shift: SHIFT1 

At Harley-Davidson, we are building more than machines. It’s our passion and commitment to continue the evolution of this storied brand, and heighten the desirability of the Harley-Davidson experience. To keep building our legend and leading our industry through innovation, evolution, and emotion we need the best and brightest talent. We stand for the timeless pursuit of adventure. Freedom for the soul. Are you ready to join us?

The Harley-Davidson Motor Company Product Development Center (PDC) located in Wauwatosa, WI is home to the mantra – You dream it. We build it. Join our team as a  Sr Engineer Materials - Aluminum Systems.

Job Summary

The Senior Materials Engineer is responsible for supporting the Product Development Process by providing deep technical expertise in aluminum materials, with a strong emphasis on cast aluminum components and systems. This role partners with product development, manufacturing, and suppliers to ensure robust material selection, processing, and performance. The engineer leads material-related problem solving, including failure analysis and root cause investigations, with a focus on improving aluminum casting quality and reliability in motorcycle applications.

Job Responsibilities

Core Responsibilities:

  • The role requires strong applied knowledge of aluminum alloys, including how composition, microstructure, and processing influence performance in real-world applications. The engineer will guide material selection and design decisions based on component requirements, particularly for structural and cosmetic cast aluminum parts.
  • A key expectation is expertise in aluminum casting processes such as high-pressure die casting, permanent mold casting, and sand casting, including an understanding of common defect modes, process controls, and quality risks. The engineer will work closely with suppliers and manufacturing teams to improve casting quality, resolve defects, and support process development.
  • The position also includes technical leadership of failure analysis and root cause investigations related to aluminum components. This includes metallurgical evaluation, interpretation of lab results, and clear documentation of findings with actionable recommendations.
  • The engineer will apply knowledge of heat treatment and thermal processing specific to aluminum alloys, including how these processes affect strength, durability, and dimensional stability. Familiarity with corrosion behavior and surface treatments for aluminum is also expected, particularly as it relates to product durability and appearance.
  • In collaboration with design and validation teams, the engineer supports understanding of mechanical behavior, including fatigue performance, and how it relates to casting quality, defects, and service loading conditions.
  • This role requires close cross-functional engagement, providing technical guidance to engineering teams, supporting supplier quality improvements, and ensuring alignment between design intent and manufacturing capability.

Laboratory & Analytical Capability

  • The candidate should be comfortable working with standard metallurgical and analytical tools to evaluate aluminum materials, including techniques such as optical emission spectroscopy, microscopy, and fractography. The ability to interpret results and connect laboratory findings to real-world component performance is essential. Candidate must be willing to perform preventive maintenance on lab equipment, plan for ordering necessary lab equipment, and keep track of budget expenses. 

Leadership & Communication

  • This role serves as a technical advisor in aluminum materials, providing guidance across engineering teams and mentoring others as needed. The candidate must be able to communicate technical findings clearly and effectively to both technical and non-technical stakeholders.
Education Requirements
Bachelor's Degree Required
Education Specifications

Bachelor’s degree in Materials Engineering, Metallurgy, or a related field is required.

Experience Requirements

A minimum of five years of experience in materials engineering is required, with demonstrated hands-on experience in aluminum materials and casting processes, preferably in product development or manufacturing environments.

Applicants must be authorized to work in the United States.

The pay range shown represents the national average pay range for this role. Your pay may be more or less than the stated range and is dependent on your geographic location and level of experience.

We offer an inclusive compensation package for all full-time salaried employees including, but not limited to, annual bonus programs, health insurance benefits, a 401k program, onsite fitness centers and employee stores, employee discounts on products and accessories, and more. Learn more about Harley-Davidson here. 

Applicants must be currently authorized to work in the United States.

Direct Reports: Yes  
Travel Required: 0 - 10%  
Pay Range: $93,400 - $145,000 
Visa Sponsorship: This position is not eligible for visa sponsorship or visa transfer  
Relocation: This position is eligible for domestic relocation assistance (within posted country)  

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