{"id":1630842,"url":"https://alion.io/job/chromalloy-aerospace-process-engineer-thermal-spray-coating","title":"Aerospace Process Engineer - Thermal Spray Coating","company":{"id":2389079,"name":"Chromalloy","domain":"chromalloy.com","url":"https://alion.io/company/chromalloy","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Dayforce","truth_index":{"grade":"A","score":98,"open_postings":112,"ghost_share":0,"stale_share":0.089,"repost_share":0.018,"time_to_fill_p50_days":27,"computed_at":"2026-10-25T05:49:26Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"middle","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Windsor, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":74000,"max_usd":134000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":4013},"experience_years_min":3,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Siemens NX","optional":true}],"status":"live","first_seen_at":"2026-09-02T07:00:00Z","employer_posted_date":"2026-10-20","last_verified_at":"2026-10-25T05:17:19Z","board_verified":true,"closed_at":null,"days_open":53,"trust":{"level":"ok","repost_count":1,"flags":[],"days_open":52},"description":"Job Summary\nWe’re looking for a Thermal Spray Process Engineer to support the repair and overhaul of critical gas turbine engine components used in commercial aerospace applications. In this role, you will develop, optimize, and sustain manufacturing processes related to surface preparation, masking, thermal spray coating application, robotic programming, and process control. Your work will directly impact product quality, performance, turnaround time, delivery, and operational efficiency while helping ensure the reliability of components that support aviation safety worldwide.\n\nWork That Matters\nAt Chromalloy, your work directly supports aviation safety and reliability. Our teams repair and manufacture critical aerospace components used across the global aviation industry. Whether you're improving processes, supporting operations, solving technical challenges, or driving business performance, your contributions help keep aircraft flying safely around the world.\n\nLocation: Windsor, CT\nTravel: Occasional travel required\nSchedule: On-site \n\nWhat You’ll Be Doing\nDevelop, implement, and optimize thermal spray coating processes for aerospace gas turbine components.\nProvide day-to-day engineering support to production operations, including monitoring yield, reducing rework, and improving process capability.\nPerform root cause analysis and corrective actions to resolve process and quality issues and prevent recurrence.\nLead activities that ensure production readiness of thermal spray equipment and associated process technologies.\nDesign, develop, and implement tooling, fixtures, gauging, and process improvements that enhance safety, quality, and productivity.\nProgram and optimize 6-axis robotic systems used in thermal spray coating applications.\nDevelop spray parameters for new coating materials and continuously improve existing coating processes.\nDevelop and optimize masking and surface preparation methods, including grit blasting procedures.\nCreate and maintain process documentation, including operating procedures, work instructions, process specifications, calibration instructions, training materials, and quality records.\nSupport operator training and collaborate with maintenance teams to establish effective preventive maintenance programs.\nParticipate in Kaizen, Lean Manufacturing, and continuous improvement initiatives to improve process performance, quality, delivery, and cost.\nApply Six Sigma and DMAIC methodologies to solve complex manufacturing challenges and drive sustainable process improvements.\n\nWhat We’re Looking For\nBachelor’s degree in Engineering or a related science-based discipline such as Materials Science, Chemistry, or Physics.\n3+ years of engineering experience in a manufacturing environment; aerospace manufacturing, repair, overhaul, or gas turbine experience preferred.\nExperience supporting manufacturing operations, process development, and continuous improvement initiatives.\nKnowledge of root cause analysis, corrective action systems, and statistical problem-solving methodologies.\nFamiliarity with Lean Manufacturing principles and structured problem-solving techniques.\nStrong written and verbal communication skills with the ability to collaborate across operations, quality, engineering, and maintenance teams.\n\nNice to Have\nExperience with thermal spray equipment and coating process development.\nExperience programming and optimizing 6-axis robotic systems.\nWorking knowledge of 3D CAD software such as Siemens NX.\nKnowledge of thermal spray technologies, including:\nAtmospheric Plasma Spray (APS)\nDual Wire Arc Spray\nCombustion Spray\nExperience with aerospace masking techniques and fixturing design.\nKnowledge of surface preparation requirements, including grit blasting processes.\nExperience supporting aerospace component repair, overhaul, or manufacturing operations.\nLean Six Sigma Green Belt certification or participation in Kaizen events.\nFamiliarity with aerospace quality systems and process control methodologies.\n\nWork Environment & Physical Requirements\nWork is performed in both office and manufacturing environments with exposure to production equipment, machinery, and industrial processes.\nRegular interaction with production areas, laboratories, and repair operations is required.\nAbility to stand, walk, bend, reach, and move throughout manufacturing facilities for extended periods.\nAbility to occasionally lift and carry up to 25 pounds.\nMust be able to wear required personal protective equipment (PPE) and comply with all safety policies and 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