Senior Materials Engineer, Metals

ABOUT THE JOB

Anduril's Materials & Process Engineering Team is seeking a metallurgical expert specializing in castings and welding to join our rapidly growing team in Costa Mesa, CA. As we scale production of advanced defense systems, the integrity of our cast and welded structures becomes paramount. You'll own the complete lifecycle of cast and welded components—from material selection through qualification, production, and field performance. The right person doesn't just know the standards; they understand the metallurgical fundamentals that explain why the standards exist and when it's appropriate to exceed them.

WHAT YOU'LL DO

• Own casting (investment, sand, permanent mold, die) and welding (fusion and solid-state) processes from concept through production across aluminum, steel, titanium, and nickel-based alloys.
• Establish internal specifications, test protocols, and acceptance criteria for castings and welds tailored to mission requirements. Define "right-sized solutions" —backed by data and first principles—when industry standards fall short or prove excessive.
• Lead supplier qualification of foundries and welding shops, transforming vendors into strategic partners through technical assessment and development.
• Design and execute characterization programs using metallography, SEM/EDS, mechanical testing, NDT (RT, UT, PT, MT), and failure analysis.
• Partner with design teams during early development to influence geometry, joint design, and specifications before drawings are released, preventing costly redesigns.
• Lead root cause investigations —systematically identifying failure mechanisms and implementing corrective actions that address root causes.
• Develop tools, templates, databases, and training materials that build organizational capability. Mentor junior engineers in metallurgical fundamentals.
• Use first principles physics as a basis for every decision.

REQUIRED QUALIFICATIONS

• Bachelor's or higher in Materials Engineering, Metallurgical Engineering, Welding Engineering, or related discipline.
• Minimum 7-10 years of hands-on industry experience with castings and/or welding in aerospace, defense, marine, or similarly demanding applications.
• Demonstrated ownership of cast or welded structures through complete product lifecycle, from development through production and field performance.
• Deep metallurgical knowledge of solidification phenomena, weld metallurgy, HAZ behavior, residual stresses, and failure mechanisms specific to castings and welds.
• Practical expertise developing weld procedures (WPS/PQR), casting process parameters, and qualification testing per relevant standards (AWS, AMS, MIL-STD).
• Proficiency interpreting engineering drawings including weld symbols, GD&T, and casting tolerances. Ability to guide design engineers on proper specification of casting and welding requirements.
• Strong analytical and troubleshooting skills with systematic problem-solving approach.
• Excellent communication skills across technical levels, from design engineers to executive leadership.
• Eligibility to obtain and maintain a U.S. Top Secret security clearance.

PREFERRED QUALIFICATIONS

• Proven track record with structural castings or welds in marine or aerospace applications under complex loading or corrosive environments.
• Direct experience with advanced processes (investment casting, friction stir welding, electron beam/laser welding, dissimilar metal joining).
• Hands-on capability in welding or casting process execution—running trials and adjusting parameters.
• Experience establishing material property databases or design allowables (A-basis, B-basis) per MMPDS or CMH-17.
• Familiarity with CAD software (NX, SolidWorks, CATIA) or simulation tools (casting simulation, weld distortion prediction).
• Active participation in technical societies (AWS, AFS, TMS, ASM) or standards committees.