Intern Failure Analysis Engineer Jobs in Illinois

About Us:

Founded on a commitment to relentless, continuous operational improvement and extraordinary customer service, we at Pursuit Aerospace pride ourselves on competitive cost structures, exceptional on-time delivery, and industry-leading quality.

The Pursuit family of companies has cultivated long-term relationships with our customers around the world through respect, teamwork, technology, and trust. We are driven to develop industry-leading process innovations and manufacturing techniques on behalf of our customers.

About the Opportunity:

We're looking for a Metallurgical Engineer to join our team at Pursuit - Larson Forgings in Chicago, IL.

This site generates approximately $35 million in annual revenue and plays a critical role in our ability to deliver seamless, open-die ring-rolled forgings for aerospace applications.

In this role, you'll be responsible for ensuring metallurgical integrity throughout the forging and heat-treatment processes. You will play a hands-on role in order review, process development, materials testing, failure analysis, and root cause investigations, working in close collaboration with engineering, quality, operations, and customers.

At Pursuit Aerospace, we value problem-solvers with a proactive mindset-those who thrive in fast-paced environments and are passionate about making things better. If you're a detail-oriented quality professional who takes pride in helping teams solve tough problems and get things right the first time, this could be the right next step for you.

Responsibilities:

• Review and interpret customer PO's, specifications, drawings, process requirements, and quality clauses.
• Review shop orders/travelers for adherence to applicable customer requirements and to ensure instructions meet internal standards.
• Develop, approve, and maintain metallurgical process instructions and fixed processes.
• Manage metallurgical test plans and coordinate subcontracted testing services.
• Prepare metallurgical documentation, material certifications, and support First Article Inspection Reports (FAIRs) and PPAPs.
• Review and disposition nonconforming material, develop rework instructions as necessary to bring material back into conformance.
• Oversee metallurgical aspects of manufacturing processes, including forging, heat treating, and metallurgical testing of aerospace components.
• Support new product introduction (NPI) through review of RFQ's and participating in long-term improvement projects.
• Ensure compliance with applicable aerospace industry standards and customer-specific quality requirements, including AS9100, ISO 9001, AMS specifications, and NADCAP.
• Work with Plex, Larson's ERP manufacturing software, to perform necessary daily duties.
• Develop and optimize forging and heat treatment procedures for various aerospace alloys.
• Collaborate with operations, quality, and suppliers to improve process capability and product conformance.
• Collaborate with Sales and Program Management to provide technical support.
• Oversee in-house microstructural evaluations, mechanical testing (hardness, tensile), and failure analysis.
• Lead root cause analysis for material-related non-conformances and implement corrective actions using structured tools (5 Whys, Fishbone, 8D).
• Support internal and external audits, including NADCAP, AS9100, and customer audits.
• Participate in continuous improvement initiatives (Kaizen, waste reduction, process optimization) to enhance product quality and operational efficiency.
• Ensure compliance with safety, environmental, and company standards.

Reasonable accommodations may be made to enable individuals to perform the essential functions.

Required Qualifications:

• Bachelor's degree in Metallurgy, Materials Science, Materials Engineering, or related technical field.
• 3+ years of experience in engineering or metallurgy within a metals manufacturing environment (forging, casting, heat treatment, machining-aerospace preferred).
• Equivalent combinations of education and experience will be considered.
• Must be authorized to work in the U.S. on a full-time bases without sponsorship now or in the future. The Company cannot offer employment to visa holders who require employer sponsorship in the future or cannot work now on a full-time basis.
• Must be able to perform work subject to ITAR/EAR regulations

Preferred Qualifications:

• Strong understanding of material properties, heat treatment processes, and mechanical testing.
• Ability to read and interpret technical drawings, blueprints, and material specifications.
• Experience with metallurgical lab testing methods (microscopy, hardness testing, failure analysis).
• Knowledge of metallurgical process controls and material specifications.
• Familiarity with ERP/MRP systems (Plex experience a plus).
• Strong analytical and problem-solving skills with attention to detail.
• Clear and effective technical communication skills.
• Experience working with quality systems and standards (AS9100, Nadcap, or ISO 9001).
• Understanding of forging, ring rolling, and material flow characteristics.
• Experience performing root cause analysis and corrective action (8D, A3, DMAIC, or similar).
• Familiarity with nondestructive testing methods (UT, MT, RT, PT).
• Experience with aerospace customer specifications (GE, Pratt & Whitney, Rolls-Royce, Safran, etc.) preferred.
• Exposure to APQP tools such as FMEA, control plans, and PPAP.
• CAD experience (AutoCAD or similar) a plus.

Working Conditions:

• This role requires up to 5% travel, including visits to other company sites, suppliers, or industry events as needed.
• Working conditions typically include both office and shop floor environments.
• Personal protective equipment (e.g., safety glasses and safety shoes) is required on the shop floor.
• Lifting up to 20-30 lbs. may be occasionally required.
• Occasional weekend and evening work may be required to accommodate priorities, deadlines, and schedules.

Compensation & Benefits:

We offer a competitive salary and benefit package, including health and disability insurance, employer-funded retirement contribution, paid time off, and company-paid holidays.

Must be willing and able to work onsite full-time in Chicago, IL. This position is eligible for relocation support.

Equal Opportunity Employer:

Pursuit Aerospace is an Equal Opportunity Employer. We adhere to all applicable federal, state, and local laws governing nondiscrimination in employment, and we do not tolerate workplace harassment based on race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, genetic information, disability, or veteran status.