This Advanced Materials Science Engineer supports the materials backbone of the KARNO Power Module, developing, testing, and qualifying the advanced metallic alloys that keep the system running cleanly and efficiently. You'll dive into how these materials behave under extreme heat, high loads, and rapid cycling, then turn that insight into practical design guidance, additive manufacturing parameters, and durability improvements that directly influence engine performance. Day-to-day, you'll work closely with the KARNO engineering teams - mechanical, thermal, design, and additive - to evaluate new alloys, validate new processes, and help build Hyliion's internal additive materials program from the ground up. If you're energized by pushing high-temperature metals to their limits and shaping how next-generation power hardware is engineered, you'll have a big impact here.
Duties and Responsibilities:
• Material Selection, Qualification & Behavior: Lead the evaluation and down-selection of high-temperature alloys, stainless steels, ceramics, coatings, and composites for critical KARNO components. • Define material requirements based on thermal, mechanical, oxidation, and fatigue loads. • Conduct microstructural and mechanical characterization to confirm performance against lifecycle and durability targets.
Testing, Characterization & Analysis:
• Plan and execute material tests including tensile, creep, fatigue, thermal cycling, hardness, and corrosion/oxidation evaluations. • Use metallography, SEM/EDS, and other microstructural methods to understand material behavior and property changes under operating conditions. • Support nondestructive evaluation (NDE) approaches when required.
Additive Manufacturing Support:
• Assess metal powders, powder behavior, and printability for powder-bed and DED additive systems. • Work directly with AM engineers to connect material properties with parameter development, heat-treatment cycles, and post-processing requirements. • Verify that process changes, maintain material integrity and meet downstream performance demands.
Failure Analysis & Quality Control:
• Investigate component or material failures using microstructural analysis, fracture mechanics, and material degradation models. • Translate findings into improved designs, tighter process controls, or updated material specifications.
Research, Development & Process Improvement:
• Drive R&D efforts for next-generation materials suitable for high-efficiency distributed power generation. • Collaborate with design, thermal, combustion, and mechanical teams to create data-driven material strategies. • Improve welding, joining, heat-treat, and fabrication practices to increase durability and manufacturability.
Cross-Functional Collaboration & Documentation:
• Prepare clear technical reports, specifications, and test summaries. • Work with suppliers, powder vendors, and external labs to qualify materials and coatings. • Ensure all material documentation aligns with ASTM, ASME, and internal engineering standards.
Qualifications:
Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
Education, Experience and Certifications:
• Bachelor's in metallurgical engineering or materials science degree required • 5+ years working with metals and materials characterization (graduate research counts) • Strong background in material behaviors such as fatigue, creep, oxidation, and thermal-mechanical degradation • Experience supporting additive manufacturing materials or metal powder evaluation is strongly preferred
Skills and Abilities:
• Hands-on experience with mechanical testing, microstructural evaluation, and failure analysis • Understanding of how material properties change with heat treatment, AM process changes, or post-processing steps • Familiarity with high-temperature alloys, surface treatments, coatings, and joining methods • Ability to evaluate metal integrity when parameters or processes shift • Strong analytical and problem-solving ability • Clear, concise technical communication • Comfortable working across disciplines (AM, thermal, mechanical, combustion, suppliers) • Detail-oriented with a research-driven mindset
Why This Role Matters:
The KARNO generator relies heavily on advanced materials capable of withstanding extreme loads. Your work will directly shape component durability, AM process capability, and overall system efficiency. This is a chance to influence material decisions that sit at the core of Hyliion's power-generation technology.
Role Classification and Working Conditions:
This is a salaried, exempt-level position. This position typically works in an office environment; and given the nature of our business is also exposed to operations/warehouses/production environments.
Physical/Other Requirements:
• Ability to lift and/or move up to 50 pounds • Ability to travel domestically, as needed, by plane, automobile, etc. approximately 30% of the time