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GE Vernova · 7 hours ago

Lead Manufacturing Engineer – Coating Process Development

Greenville, SC

Full-time

Onsite

Mid, Senior Level

$82K/yr - $137K/yr

4+ years exp

GE Vernova is focused on innovation in electrification and decarbonization. The Lead Manufacturing Engineer will be responsible for developing and industrializing manufacturing processes, specifically focusing on thermal spray coating processes for gas turbine components, while ensuring quality and efficiency in production.

EnergyEnergy EfficiencySustainability

No H1B

U.S. Citizen Only

Responsibilities

Drive process development in GVL site, converting a ‘lab-proven’ parameters into stable and documented production processes

Develop and qualify HVOF and APS coating processes

The process transfer must be performed with a focus to the ‘Frozen Process’ standards to the thermal spray critical parameters and at the same time understanding the process levels of freedom to optimize the process meets the print and specification requirements

Coating process development includes a large scope of operations such as masking, grit blasting, qualify inspections, post coating final surface finish, and heat treatments for bond coat and topcoat

Capability to operate thermal spray cells, solid understanding of thermal spray parameters and their influence on the coating process sustainability

Validate robot programs and support robotic programming

Identify potential ways to optimize the coating program to improve the cycle time or eliminate coating defects

Thorough understanding of coating cell components and their interactions is required

The candidate should be capable of diagnosing equipment or process issues and executing corrective and preventive actions to ensure long-term process stability

In-depth expertise in microstructure evaluation and mechanical testing (hardness and tensile strength) is essential

The candidate must be able to perform root cause analysis of coating defects (e.g., metallic and TBC ceramic coatings porosity, DVC spacing, lamellar structure, poor adhesion, oxidation, pull-outs, unmets) based on microstructural evidence, requiring a comprehensive understanding of how thermal spray process parameters affect coating microstructure

Hands-on experience in a metallographic lab, including knowledge of the purpose and operation of standard laboratory equipment used in sample preparation and analysis

Perform optical metallography, porosity, DVC microstructural features, microhardness testing to assess coating quality

Develop and optimize, tooling, and masking to ensure repeatability, standoff control, and overspray containment

Translate CAD concepts into tested, production-ready tooling solutions

Responsible for process industrialization and scale-up activities based on 10-steps standard, including creation of control plans, process gap identification, detailed work instructions, and comprehensive operator training materials

Support implementation of SPC and lead NPI transfers, ensuring readiness for full-scale production and compliance with internal and external audits

Partner with the process qualification team to determine coating process readiness by analyzing Cp and Cpk metrics

Use insights from eCAV data to identify improvement opportunities and implement changes to enhance first-pass yield (FPY)

Lean Manufacturing & Process Flow

Leverage Lean manufacturing concepts such as takt time, value stream optimization, and waste reduction to enhance operational efficiency

Work cross-functionally to implement workflows that improve throughput without compromising safety or product quality

Collaborate across R&D, engineering, QA, operations, suppliers, and customers to ensure alignment on project goals and timelines

Present complex data and insights in a clear, concise manner tailored to technical and non-technical stakeholders

Qualification

Thermal Spray DevelopmentCoating Process DevelopmentMicrostructure EvaluationLean ManufacturingMetallographic AnalysisRobotic ProgrammingCAD SoftwareFMEANondestructive InspectionSix Sigma CertificationCommunication SkillsProblem SolvingCollaboration Skills

Required

Bachelor's degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, or related field (advanced degree preferred)

4+ years of hands-on thermal spray process development experience (HVOF & APS)

Strong skills in coating microstructure evaluation and metallographic analysis (optical, image analysis)

Excellent written and verbal communication skills; proven track record working in multi-group environments toward shared goals

Ability and desire to work on site in a manufacturing environment

Ability to work off-shift or flexible schedule at times as required by project timelines

Must be legally authorized to work in the USA without sponsorship now or in the future

This position is 100% onsite at our GE Vernova Greenville, SC site

This role is restricted to U.S. persons (i.e., U.S. citizens, permanent residents, and other protected individuals under the Immigration and Naturalization Act, 8 U.S.C. 1324b(a)(3)) due to access to export-controlled technology