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Metallurgy Process Engineer Jobs in Washington, DC

Aurora Flight Sciences

Structures Engineer

Manassas, VA · On-site

$92K - $164K/yr

... metallic and composite components. Preferred Requirements -Demonstrate proficiency in FEM ... processes, etc.). -Automate workflows for speed and efficiency using Microsoft Office 365, VBA ...

ICF

On Call Critical Minerals Expert - Remote

Washington, DC · On-site +1

$20.50 - $21/hr

Processing, separation, refining, and metallurgy innovation * Battery, magnet, and advanced ... Bachelor's degree in a relevant field such as mining engineering, geology, metallurgical/materials ...

Equiliem

Manufacturing Technician II

Hanover, MD

$28 - $30/hr

Read and interpret engineering drawings, blueprints, work instructions, and manufacturing ... Operate manufacturing equipment used for processing composite, metallic, and other aerospace ...

Electra

Senior Airframe Design Engineer

Manassas, VA · On-site

$100K - $136K/yr

... processes. * Stay informed on emerging technologies, advanced materials, and evolving FAA ... Strong understanding of airframe structural design for both metallic and composite components.

Electra

Airframe Design Engineer

Manassas, VA · On-site

$92K - $112K/yr

Support CAD admin duties such as tool and process development for designers Required Education and ... Strong understanding of airframe structural design for both metallic and composite components.

Electra

Airframe Design Engineer

Manassas, VA · On-site

$92K - $112K/yr

Support CAD admin duties such as tool and process development for designersRequired Education and ... metallic and composite components.Demonstrated experience across conceptual, preliminary, and ...

Electra

Senior Airframe Design Engineer

Manassas, VA · On-site

$100K - $136K/yr

... metallic and composite components.Demonstrated experience across conceptual, preliminary, and ... Familiarity with composite manufacturing processes such as AFP, infusion, or hand layup.Experience ...

Forgent

Fabrication & Manufacturing Engineer

Hanover, MD · On-site

$100K - $115K/yr

Create processes for operators to physically measure and audit the very first part that comes off ... metallurgy. o Blueprint Literacy: Absolute mastery of reading complex geometric dimensioning and ...

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Showing results 21-40

All JobsMetallurgy Process Engineer JobsMetallurgy Process Engineer Jobs in Washington, DC

Metallurgy Process Engineer information

See Washington, DC salary details

$56.1K

$104.2K

$161.4K

How much do metallurgy process engineer jobs pay per year?

As of Aug 8, 2026, the average yearly pay for metallurgy process engineer in Washington, DC is $104,219.00, according to ZipRecruiter salary data. Most workers in this role earn between $84,400.00 and $116,700.00 per year, depending on experience, location, and employer.

What does a metallurgy process engineer do?

A Metallurgy Process Engineer is responsible for developing, optimizing, and overseeing processes involved in the extraction, refining, and manufacturing of metals and alloys. They work to improve efficiency, quality, and safety in metallurgical operations, such as smelting, casting, and heat treatment. Metallurgy Process Engineers also troubleshoot production issues, ensure compliance with environmental and safety regulations, and collaborate with other engineers to develop new materials or processes.

What is the difference between Metallurgy Process Engineer vs Materials Scientist?

AspectMetallurgy Process EngineerMaterials Scientist
CredentialsBachelor's or Master's in Metallurgy, Materials Science, or related fieldBachelor's or Master's in Materials Science, Chemistry, or Physics
Work EnvironmentIndustrial settings, manufacturing plants, metal production facilitiesResearch labs, academic institutions, R&D departments
Industry UsageMetal production, mining, manufacturingResearch, development, academia

Metallurgy Process Engineers focus on optimizing metal production processes in industrial settings, while Materials Scientists primarily conduct research to develop new materials and improve existing ones. Both roles require a strong understanding of material properties but differ in their work environment and application focus.

What are the key skills and qualifications needed to thrive as a metallurgy process engineer, and why are they important?

To thrive as a Metallurgy Process Engineer, a strong background in materials science, metallurgy, and chemical engineering is essential, typically supported by a relevant bachelor's degree. Familiarity with metallurgical analysis tools, process simulation software, and industry certifications like Six Sigma are commonly required. Strong problem-solving abilities, attention to detail, and effective communication skills help professionals excel in cross-functional teams and complex manufacturing environments. These competencies are crucial for optimizing metal production processes, ensuring product quality, and driving operational efficiency.

What are some typical challenges faced by metallurgy process engineers in optimizing industrial processes?

Metallurgy Process Engineers often encounter challenges such as balancing cost efficiency with maintaining material quality, adapting processes to new alloys or specifications, and troubleshooting unexpected production issues like contamination or equipment wear. They must continuously monitor process parameters, analyze data, and implement improvements while collaborating closely with production teams and quality control. Staying updated with the latest technological advancements and environmental regulations is also crucial to ensure processes remain competitive and compliant.
What are popular job titles related to Metallurgy Process Engineer jobs in Washington, DC? For Metallurgy Process Engineer jobs in Washington, DC, the most frequently searched job titles are:
What job categories do people searching Metallurgy Process Engineer jobs in Washington, DC look for? The top searched job categories for Metallurgy Process Engineer jobs in Washington, DC are:
Metallurgy Process Engineer jobs near you
Infographic showing various Metallurgy Process Engineer job openings in Washington, DC as of July 2026, with employment types broken down into 1% As Needed, 77% Full Time, 17% Part Time, 1% Temporary, 3% Contract, and 1% Nights. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $104,219 per year, or $50.1 per hour.

Senior/Principal Airframe Stress Engineer

Electra

Manassas, VA • On-site

$130K - $180K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Posted 8 days ago

Job description

About Electra
At Electra, we're building hybrid-electric Ultra Short Takeoff and Landing aircraft that redefine regional air travel. Our technology enables aircraft to take off and land in soccer field-sized spaces, unlocking thousands of new operating locations and enabling what we call Direct Aviation: quiet, efficient, point-to-point travel closer to where people live and work.
A global company headquartered in Manassas, VA, with additional operations in Switzerland, Electra is backed by industry leaders and is advancing toward certification. We're a growing team of innovators working at the forefront of sustainable aviation-every hire plays a critical role in shaping the future of flight.
The Role
As a Senior or Principal Airframe Stress Engineer, you will lead structural analysis efforts supporting the development, certification, and production of Electra's flagship hybrid-electric eSTOL aircraft. This role is responsible for ensuring the structural integrity of metallic and composite airframe components through detailed analysis, testing, and certification substantiation.
You will work closely with design engineering, loads, materials & processes, manufacturing, structural test, suppliers, and certification teams to develop robust airframe structures that meet performance, safety, and FAA certification requirements. The ideal candidate combines deep structural analysis expertise with strong engineering judgment and the ability to influence aircraft design decisions throughout the product lifecycle.
What You'll Do
  • Support development of major airframe structures from preliminary design through certification, production launch, and manufacturing ramp-up
  • Perform static strength, fatigue, and durability analyses for metallic and composite aircraft structures
  • Develop structural substantiation methods and analysis plans supporting FAA Part 23 type certification
  • Create and validate finite element models using FEMAP/Nastran or equivalent analysis tools
  • Perform detailed hand calculations using industry-standard methodologies and references including:
    • Bruhn
    • Niu
    • Roark
    • ESDU
    • Classical mechanics of materials approaches
  • Collaborate with loads, design, materials & processes, manufacturing, structural test, and certification teams throughout the entire development process
  • Support trade studies and structural design optimization activities
  • Define structural analysis requirements and certification substantiation plans
  • Review and approve design dispositions and engineering analyses
  • Support component, subassembly, and full-scale structural testing activities, including:
    • Test planning
    • Requirements definition
    • Instrumentation support
    • Data review
    • Test reporting
  • Prepare structural substantiation reports and certification documentation
  • Present structural analyses and recommendations during internal and external design reviews
  • Support supplier technical reviews and provide guidance on structural analysis methodologies
  • Contribute to the establishment of structural analysis processes, best practices, and design standards
What You'll Bring
  • Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related engineering discipline
  • Experience in airframe structural analysis supporting aircraft development programs
  • Strong knowledge of metallic and composite aircraft structures
  • Experience supporting FAA Part 23 and/or Part 25 aircraft certification programs
  • Advanced proficiency with FEMAP/Nastran or equivalent finite element analysis tools
  • Experience with NX or similar CAD platforms
  • Strong understanding of:
    • Aircraft loads
    • Free body diagrams
    • Structural load paths
    • Mechanics of materials
    • Structural stability and failure modes
  • Advanced proficiency performing both hand calculations and finite element analyses
  • Experience developing structural substantiation reports and certification documentation
  • Strong technical writing and communication skills
  • Ability to work effectively within multidisciplinary engineering teams
  • Strong analytical and problem-solving capabilities
Preferred Qualifications
  • Master's degree in Aerospace Engineering, Mechanical Engineering, or related discipline
  • Experience supporting aircraft programs from conceptual design through certification and production
  • Experience with composite airframe design and certification
  • Experience supporting structural testing and correlation of analytical models
  • Familiarity with hybrid-electric, eSTOL, eVTOL, or advanced air mobility aircraft programs
  • Experience working directly with regulatory authorities during certification efforts
  • Experience mentoring engineers and reviewing structural analyses
  • U.S. Person (U.S. Citizen or Green Card holder) preferred
Location & Travel
Location: Manassas, VA Headquarters. This position requires regular onsite presence to support collaboration with engineering, manufacturing, and test teams.
Travel: Minimal
Leveling Expectations
Level (Senior or Principal) will be determined based on the candidate's experience, technical expertise, demonstrated leadership, and ability to influence aircraft development decisions.
Both levels require expertise in aircraft structural analysis, certification substantiation, and aircraft development. Differentiation is based on technical leadership, scope of responsibility, independence, and organizational influence.
Senior Airframe Stress Engineer (8+ Years)
  • Demonstrates strong expertise in aircraft structural analysis and airframe certification
  • Independently performs static, fatigue, and damage tolerance analyses
  • Develops structural substantiation packages for FAA certification activities
  • Creates and validates finite element models and analytical methodologies
  • Collaborates effectively across design, loads, certification, and test organizations
  • Supports structural testing, correlation activities, and certification efforts
  • Provides technical guidance within assigned programs and workstreams
  • Drives resolution of complex structural engineering challenges with minimal supervision
Principal Airframe Stress Engineer (10+ Years)
  • Recognized subject matter expert in aircraft structural analysis and certification
  • Leads major structural development efforts across large airframe assemblies and programs
  • Establishes structural analysis methodologies, standards, and best practices
  • Serves as a key technical authority for certification substantiation strategies
  • Drives structural architecture decisions balancing weight, manufacturability, performance, and certification requirements
  • Leads critical technical reviews and influences program-level engineering decisions
  • Mentors engineers across the organization and elevates overall technical capability
  • Acts as a primary interface with certification authorities, suppliers, and external partners on structural matters
  • Provides strategic technical leadership throughout aircraft development, certification, and production readiness efforts
Compensation
$130,000.00 - $180,000.00 annually This range reflects the anticipated hiring range across all eligible locations; actual compensation is determined based on relevant experience, education, skills, level, and geographic location. Total compensation includes performance bonus, equity eligibility, and comprehensive benefits.
What We Offer
  • Competitive salary and equity
  • Medical, dental, and vision insurance; STD, LTD, and life insurance
  • Generous PTO, sick leave, and company holidays
  • Paid winter break
  • 401(k) with immediate vesting
  • Free catered lunches, coffee, snacks, and drinks at our Manassas headquarters
  • Free on-site parking
  • Opportunity to help design, certify, and bring to market a groundbreaking hybrid-electric aircraft that will redefine regional air mobility through Direct Aviation.

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