Distinguished R&D Staff - Extreme Environment Metals Processing

Requisition Id15112

Overview:

The Deposition Science & Technology (DS&T) Group within the Manufacturing Science Division (MSD) at Oak Ridge National Laboratory (ORNL) is seeking a Distinguished Research Staff Member with extensive experience in the melting and casting, powder feedstock manufacture and characterization, and additive manufacturing of materials for extreme environments, with an emphasis on nickel and refractory materials to support national priorities in advanced manufacturing, energy, and defense.

This position directly contributes to programs at the Manufacturing Demonstration Facility (MDF), the Department of Energy's (DOE) premier institute for scaling and deploying additive manufacturing (AM) technologies. You will lead the development of feedstocks for extreme environment metals to meet the needs for advanced manufacturing processing. This role provides the opportunity to drive materials innovation for extreme environments, with impact across DOE mission areas, and with strategic industrial partners.

Major Duties/Responsibilities:

• Lead research in melting, casting, and alloying of refractory metals (e.g., W, Mo, Ta, Nb) using vacuum arc remelting, electron beam, plasma, or induction furnaces.
• Drive feedstock development for additive manufacturing programs, ensuring powders meet performance requirements for laser powder bed fusion (LPBF), directed energy deposition (DED), and other advanced AM modalities.
• Integrate powder R&D efforts with MDF pilot-scale AM capabilities, including powder reuse studies, flowability optimization, and material qualification.
• Collaborate with multidisciplinary teams to support supply chain resilience and domestic production capabilities of strategic refractory materials for defense systems.
• Utilize characterization techniques (e.g., SEM, XRD, ICP-MS, EBSD, etc) to assess chemical purity, microstructure, and thermal/mechanical properties.
• Serve as Principal Investigator (PI) on DoD and DOE-funded programs, lead proposal efforts and strategic collaborations with federal agencies and industrial partners.
• Mentor early-career researchers, postdocs, and students, while supporting an inclusive and collaborative workplace.
• Deliver ORNL's mission by aligning behaviors, priorities, and interactions with our core values of Impact, Integrity, Teamwork, Safety, and Service. Promote equal opportunity by fostering a respectful workplace - in how we treat one another, work together, and measure success.

Basic Qualifications:

• A Ph.D. in Materials Science, Metallurgical Engineering, or a closely related field with 12+ years of relevant research experience; or M.S. with 16+ years of applied experience in materials processing or manufacturing.
• Proven expertise in extreme environment metal melting and powder synthesis, including experience with vacuum/inert atmosphere systems.
• Proven experience in the operations of additive manufacturing systems
• Strong track record of technical leadership, peer-reviewed publications, and program development.
• Ability to obtain and maintain a DOE Q clearance (required for work involving export-controlled and classified materials).

Preferred Qualifications:

• A demonstrated experience in developing AM feedstocks tailored to performance requirements.
• Experience working in or collaborating with universities, industry, and national laboratories.
• Experience managing multidisciplinary teams and contributing to cross-party initiatives.
• Excellent written and oral communication skills.
• Motivated self-starter with the ability to work independently and to participate creatively in collaborative teams across the laboratory.
• Ability to function well in a fast-paced research environment, set priorities to accomplish multiple tasks within deadlines, and adapt to ever changing needs.

Special Requirements:

Visa sponsorship is not available for this position.

This position requires the ability to obtain and maintain a clearance from the Department of Energy. As such, this position is a Workplace Substance Abuse (WSAP) testing designated position. WSAP positions require passing a pre-placement drug test and participation in an ongoing random drug testing program.

About ORNL:

As a U.S. Department of Energy (DOE) Office of Science national laboratory, ORNL has an impressive 80-year legacy of addressing the nation's most pressing challenges. Our team is made up of over 7,000 dedicated and innovative individuals! Our goal is to create an environment where a variety of perspectives and backgrounds are valued, ensuring ORNL is known as a top choice for employment. These principles are essential for supporting our broader mission to drive scientific breakthroughs and translate them into solutions for energy, environmental, and security challenges facing the nation.

ORNL offers competitive pay and benefits programs to attract and retain individuals who demonstrate exceptional work behaviors. The laboratory provides a range of employee benefits, including medical and retirement plans and flexible work hours, to support the well-being of you and your family. Employee amenities such as on-site fitness, banking, and cafeteria facilities are also available for added convenience.

Other benefits include the following: Prescription Drug Plan, Dental Plan, Vision Plan, 401(k) Retirement Plan, Contributory Pension Plan, Life Insurance, Disability Benefits, Generous Vacation and Holidays, Parental Leave, Legal Insurance with Identity Theft Protection, Employee Assistance Plan, Flexible Spending Accounts, Health Savings Accounts, Wellness Programs, Educational Assistance, Relocation Assistance, and Employee Discounts.

If you have difficulty using the online application system or need an accommodation to apply due to a disability, please email: ORNLRecruiting@ornl.gov.

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This position will remain open for a minimum of 5 days after which it will close when a qualified candidate is identified and/or hired.

We accept Word (.doc, .docx), Adobe (unsecured .pdf), Rich Text Format (.rtf), and HTML (.htm, .html) up to 5MB in size. Resumes from third party vendors will not be accepted; these resumes will be deleted and the candidates submitted will not be considered for employment.

If you have trouble applying for a position, please email ORNLRecruiting@ornl.gov.

ORNL is an equal opportunity employer. All qualified applicants, including individuals with disabilities and protected veterans, are encouraged to apply. UT-Battelle is an E-Verify employer.