Metallurgical Engineer - ADL AZ

Subsidiary

Overview

The Casting Metallurgical Engineer is responsible for developing, controlling, and optimizing aluminum melting and casting processes to consistently produce high-quality ingot for can body stock applications. This role focuses on melt quality, alloy chemistry, filtration, solidification control, and defect prevention while supporting initial equipment installation, commissioning, startup, and ongoing production.

Responsibilities

• Develop, implement, and refine aluminum melting and DC casting practices consistent with the rolling mill’s melt/cast shop.
• Control alloy chemistry, furnace operations, degassing, filtration, and solidification parameters
• Monitor casting water chemistry and cooling practices to ensure process stability
• Perform melt chemistry analysis, microstructure evaluation, and mechanical testing
• Implement quality control procedures to ensure product meets internal and customer specifications
• Prepare technical reports summarizing findings, trends, and improvement recommendations
• Conduct molten metal cleanliness testing using LiMCA and PoDFA methodologies
• Apply principles of molten aluminum filtration, including deep bed and ceramic filtration systems
• Investigate casting defects such as porosity, cracking, shrinkage, and inclusions
• Perform root cause analysis and recommend corrective actions to improve yield and reduce scrap
• Work closely with production, quality, maintenance, and engineering teams
• Train production operators on melt/casting procedures, molten metal safety and quality requirements.
• Collaborate with the Aluminum Dynamics technical casting team in Columbus/Starkville, MS
• Support process optimization initiatives focused on safety, productivity, cost, and sustainability
• Manage day-to-day melting and casting practices to ensure consistent ingot quality
• Conduct metallurgical lab testing, including chemical analysis and microstructural evaluation
• Monitor and document metal cleanliness and casting process parameters
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Qualifications

Required

• Bachelor’s degree in Metallurgical Engineering, Materials Science, or a related discipline
• 2–5 years of hands-on experience in an aluminum cast house environment 

Preferred

• Strong knowledge of aluminum alloys and DC casting processes
• Experience with molten aluminum filtration and cleanliness control
• Understanding of aluminum phase diagrams, solidification behavior, and defect mechanisms
• Familiarity with industry standards (ASTM, ISO)
• Proficiency with metallurgical lab equipment (microscopes, spectrometers, LiMCA and PoDFA testing)
• Working knowledge of SPC and process data analysis tools
• Strong analytical, problem-solving, and communication skills
• Exposure to can body stock casting, rolling, finishing, or can-making operations is a plus but not required

Steel Dynamics, Inc., and all affiliated entities are equal opportunity employers.