{"id":324163,"url":"https://alion.io/job/alcoa-senior-materials-development-engineer-elysis","title":"Senior Materials Development Engineer - ELYSIS","company":{"id":4293,"name":"Alcoa","domain":"alcoa.com","url":"https://alion.io/company/alcoa","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"A","score":95,"open_postings":11,"ghost_share":0,"stale_share":0.364,"repost_share":0.091,"time_to_fill_p50_days":17,"computed_at":"2026-10-29T05:49:05Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["New Kensington, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":93000,"max_usd":175000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":6333},"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[],"status":"live","first_seen_at":"2026-08-07T00:00:00Z","employer_posted_date":"2026-10-16","last_verified_at":"2026-10-29T02:03:02Z","board_verified":true,"closed_at":null,"days_open":83,"trust":{"level":"ok","repost_count":1,"flags":[],"days_open":83},"description":"Shape Your World\nAt Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.\nSenior Materials Development Engineer - ELYSIS\nA New Era for the Aluminum Industry - ELYSIS\nCarbon Free Aluminum\nThere is a new, revolutionary way to make aluminum. It eliminates all greenhouse gases. And it produces oxygen! The ELYSIS™ technology is the greatest breakthrough in the aluminum industry since its beginnings in 1886. It has the potential to drastically reduce the environmental footprint of the global aluminum industry.\nThe ELYSIS™ technology effectively puts an end to the use of carbon anode in the aluminum smelting process. It features the newly developed breakthrough proprietary materials that are stable and do not react during the process. Thus, it eliminates all direct greenhouse gas (GHG) emissions from the aluminum smelting process and is the first technology ever that emits oxygen as its by-product.\nAn unprecedented world-class partnership of two major aluminum industry pioneers - Alcoa and Rio Tinto - led to the formation of ELYSIS, announced in 2018. The Canadian Government and the Quebec Government, through participation of Investment Quebec, have decided to support and be part of this industry revolution. The world’s technology giant Apple has helped facilitate the collaboration between Alcoa and Rio Tinto on the carbon-free smelting process and has agreed to provide ELYSIS with technical support.\nELYSIS is headquartered in Montreal, Quebec, Canada with Technology Research & Development locations in Alma, Quebec, Canada, in Jonquière, Quebec, Canada, in New Kensington, Pennsylvania, United States, and in France.\nELYSIS provides a unique solution for drastic reductions in the carbon footprint of many products used in our daily lives, including transportation, construction, electrical and consumer goods industries.\nELYSIS metal is now being used by Apple (MacBook Pro and iPhone 12 SE), Ab InBEV (cans), Audi (e-tron GT wheels), and Corona (cans).\nAbout the Location\nThe ELYSIS US Research & Development facility is in the Alcoa Technical Center (ATC) located in New Kensington, PA which is the birthplace of the aluminum industry. Near Pittsburgh, PA, the ATC is where the process being scaled-up by ELYSIS was first developed with a dedicated team who continues to reinvent the aluminum industry for a sustainable future.\nMajority of the work will be hands-on and onsite. Opportunities for remote reporting and documentation activities.\nAbout the position:\nThe Senior Materials Development Engineer will use their wide breadth of knowledge and expertise in ceramic materials and processes to lead research and development efforts associated with technical readiness level advancement of a ceramic process used to produce proprietary and novel ceramic electrodes for the Elysis smelting process. This role also serves to be the technical liaison, providing data-based decisions, guidance, and support to Elysis electrode production and industrialization teams. This role will report to Elysis R&D management.\nKey Activities / Responsibilities:\nCreates and executes technical programs aimed at reducing industrialization scale-up risks for critical equipment and processes,\nLeads projects, defines objectives, develops work plans, and conducts research that builds-off of past advances and scientific understanding of the breakthrough materials used in Elysis’s advanced smelting processes.\nProvide data-based guidance for equipment and process design that promotes an overall reduction in risk associated with industrialization of the processes associated with the Elysis technology.\nSupports the development of technical specifications for materials and key commercial scale equipment sets by executing continuous improvement initiatives, and/or creating technology development programs that identify and close specific knowledge gaps associated with existing processes or equipment sets.\nUse of a competent, hands-on approach that applies fundamental engineering principles to practical solutions and applications in laboratory, pilot, and commercial scale environments.\nUse root cause analysis tools to provide robust and sustainable solutions to new material, process, or production issues.\nSeeks-out and identifies opportunities for improvements and implements innovative solutions required to advance materials development goals and/or production initiatives required for the success of the Elysis program.\nMeets relevant project objectives by developing internal or external relationships, managing scopes, schedules, and budgets of vendors, service providers or institutions.\nOrganizes results in clear, traceable formats, communicates progress and results through written detailed technical reports, presentations, patents, and publications.\nMobility\nELYSIS is a global company with operations in Canada, France, and the United States. Business related travel and extended duration assignments or missions may be essential for the success of this role.\nAbout You\nGraduate degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.\n5-10 years of relevant work experience related to the development of ceramic materials or processes preferred.\nDemonstrated knowledge in ceramic sintering processes, processing equipment and process scale-up experience.\nProven project execution and management skills.\nStrong aptitude in physical, chemical, and thermal material property characterization methods and analysis.\nExperience working in collaborative, results driven, fast-paced team environments.\nStrong communication, organizational and analytical skills for data management, analysis, and results presentation.\nDiversity: Be Part of an Unprecedented Partnership\nAt ELYSIS we are committed to an inclusive environment where people feel comfortable to be themselves. We want our people to feel that all voices are heard, all cultures respected and that a variety of perspectives are not only welcome - they are essential to success of the unprecedented partnership that ELYSIS is.\nWe treat each other respectfully, fairly, compassionately and with dignity regardless of race, gender, nationality, ethnic origin, religion, age, sexual orientation, or anything else that makes us different. At ELYSIS, we particularly welcome and encourage applications from women, the LGBTQIA2 community, mature workers, people with disabilities and people from different cultural backgrounds. ELYSIS is proud to be an equal opportunity workplace.\nAbout the Location\nEvery day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSIS™, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process- a revolution to the aluminum industry!\nWe are values led, vision driven and united by our purpose of transforming raw potential into real progress. Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate.\nAs a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person’s gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate.\nIf you have visited our website in search of information on U.S. employment opportunities or to apply for a position, and you require an accommodation, please contact Alcoa Recruiting via email at .\nThis is a place where you are empowered to do your best work, be your authentic self, and feel a true sense of belonging. Come join us and shape your career!\nYour work. Your world. 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