Physical Metallurgist

Physical Metallurgist

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency.

As a Physical Metallurgist, you will lead thermodynamic model-supported experimental materials and process development, of high temperature metals production from oxides. You will be responsible for the process definition, continuous improvement, documentation, and scale – up of rare earth metallization.

The ideal candidate will design and execute metallurgical experiments while using thermodynamic modeling to interpret results, predict phase behavior, and accelerate process and materials development. This position works closely with process engineering, R&D, and operations teams to translate fundamental understanding into practical outcomes.

Responsibilities

• Design and conduct laboratory and pilot-scale metallization experiments

• Continuous, data driven, process improvements, and translation of pilot-scale improvements to full production, prioritizing documentation and management of change.

• Optimize salt chemistry, process conditions, and reactor geometry.

• Prepare and characterize materials using optical microscopy, SEM/EDS, XRD, and related techniques

• Develop experimental plans to validate thermodynamic predictions

• Maintain detailed experimental records and analyze results statistically and physically

• Design experimental programs to establish reactor kinetics, optimize residence time, and maximize throughput.

• Present results regularly to peers and leadership.

• Author and maintain formal process documentation suitable for training and execution by operations teams.

Partner with R&D, operations, quality, and EHS teams to ensure chemical processes are:

• Safe

• Scalable

• Cost-effective

• Environmentally compliant

• Provide technical leadership and mentorship to junior engineers and technicians.

• Use FactSage, ThermoCalc, or other CALPHAD tools to calculate phase equilibria, thermochemical properties, and reaction pathways.

• Model multi-component alloy and oxide/slag/salt systems to guide experimental design

*Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business*

Qualifications

• Master’s Degree or higher in Metallurgical Engineering, Materials Science, Chemistry or a related field

• 5+ years of hands-on experience in metallurgical or electrochemical process development or production

• Proven experience creating clear, auditable, and operator-ready process documentation.

• Experience supporting pilot plant or early commercial operations.

• Ability to independently design and execute experiments.

• Strong technical writing and communication skills.

Strong working knowledge of:

• Phase equilibria

• Design of Experiments

• Analytical techniques (SEM, XRF, ICP, etc.)

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• Experience in startup or scale-up environments

• Knowledge of quality systems (ISO, internal technical governance)

• Ability to operate as a technical authority without excessive oversight

• Knowledge of CALPHAD tools (FactSage, Thermo-Calc, or similar)

• Experience with high temperature molten salts