Thermal Spray Industrialization & Process Development Engineer

urn a thermal spray coating into a rock-solid quality, repeatable production process, we want you.

We're seeking a hands-on highly experienced Thermal Spray Industrialization & Process Development Engineer to lead the development, qualification, industrialization, and serial life production.

You will focus on High Velocity Oxy-Fuel (HVOF) and Atmospheric Plasma Spray (APS) coating processes for gas turbine high-performance components.

This role blends practical coating cell work, metallographic preparation, microstructural analysis, root-cause problem solving, and the design of fixtures/masking to enable repeatable, cost-effective production, all while operating within our SQDC (Safety, Quality, Delivery, Cost) values. You will work in a multi-disciplinary, multi-group environment, aligning R&D, manufacturing, quality, and customer teams toward a common goal, requiring clear, concise communication and strong collaboration skills.

Job Description

What you'll do

• Your main mission will be to Industrialize and scale thermal spray coating processes to support GE Vernova's largest volume expansion

• Develop, qualify, and industrialize HVOF and APS thermal spray processes from lab to full-scale production

• Understand the critical thermal spray parameters and ensure frozen process, repeatable production processes that meet print and specification requirements

• Operate and support thermal spray cells, including robotic spray programs, with a focus on quality, cycle time, and potential defect reduction and waste.

• Diagnose and resolve coating, equipment, and process issues to ensure long-term process stability

• Perform and interpret metallographic evaluations and mechanical testing to assess coating quality and lead root-cause analysis of defects

• Lead process scale-up activities, including control plans, work instructions, operator training, SPC, and NPI transfers

• Collaborate across engineering, operations, quality, and R&D to deliver results quickly in a high-volume manufacturing environment

• This role is 100% time on GE Vernova located in Greenville SC site

What you'll bring (Basic Qualifications)

• Bachelor's degree in Materials Science, Metallurgical Engineering, Mechanical Engineering, Chemical Engineering or related field (advanced degree preferred)

• Minimum 2 years of hands-on thermal spray process development experience in a manufacturing and project environment (HVOF & APS)

• Strong skills in coating microstructure evaluation and metallographic analysis (optical, image analysis)

• Excellent written and verbal communication skills; proven track record working in multi-group environments toward shared goals

• Ability and desire to work on site in a manufacturing environment.

• Ability to work off-shift or flexible schedule at times as required by project timelines

What will make you stand out

• Minimum 4 years of hands-on thermal spray process development experience in a manufacturing and project environment (HVOF & APS).

• Proven experience designing fixtures/masking for production coating applications (SolidWorks, NX or equivalent CAD).

• Background in process documentation, FMEA, control plans, and structured problem-solving (e.g., fishbone, 5 Whys, 8D).

• Experience with MCrAlY bond coats, ceramic topcoats (e.g. YSZ), coatings.

• Gas turbine or aerospace coatings qualification experience.

• Knowledge of blasting, masking, heat treatment, and post-processing of coated parts.

• Familiarity with nondestructive testing (NDT) for coatings.

• Lean/Six Sigma certification or equivalent continuous improvement experience.

Eligibility Requirement

• Must be legally authorized to work in the USA without sponsorship now or in the future

• This position is 100% onsite at our GE Vernova Greenville, SC site

• This role is restricted to U.S. persons (i.e., U.S. citizens, permanent residents, and other protected individuals under the Immigration and Naturalization Act, 8 U.S.C. 1324b(a)(3)) due to access to export-controlled technology. GE will require proof of status prior to employment

Benefits Available to You

GE Vernova employees rise to the challenge of building a world that works. In order to meet this mission, we provide varied, competitive benefits to help support our workforce: Our Culture | GE Vernova (gecareers.com)

• Our compensation & benefits are designed to reward high performers and help you manage your personal and family needs. We offer a robust benefits package depending on your employment status and your national requirements.

• A healthy, balanced lifestyle can mean different things to different people. We've created programs that support the way you live and work today.

• GE Vernova invests to provide opportunities to grow your career by providing a path for continued on-the-job learning and development.

Inclusion & Diversity

At GE Vernova, we believe in the value of your unique identity, background and experiences. We are committed to fostering an inclusive culture, where everyone feels empowered to do their best work because they feel accepted, respected and that they belong. Click here to learn more: https://jobs.gecareers.com/vernova/global/en/i-d-e

About GE Vernova Gas Power

GE Vernova's Gas Power business engineers advanced, efficient natural gas-powered technologies and services, along with decarbonization solutions that aim to help electrify a lower carbon future. It is a global leader in gas turbines and power plant technologies and services with the industry's largest installed base.

This role requires access to U.S. export-controlled information. If applicable, final offers will be contingent on ability to obtain authorization for access to U.S. export-controlled information from the U.S. Government.

Additional Information

GE Vernova offers a great work environment, professional development, challenging careers, and competitive compensation. GE Vernova is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.

GE Vernova will only employ those who are legally authorized to work in the United States for this opening. Any offer of employment is conditioned upon the successful completion of a drug screen (as applicable).

Relocation Assistance Provided: Yes

For candidates applying to a U.S. based position, the pay range for this position is between $81,700.00 and $136,700.00. The Company pays a geographic differential of 110%, 120% or 130% of salary in certain areas. The specific pay offered may be influenced by a variety of factors, including the candidate's experience, education, and skill set.

Bonus eligibility: discretionary annual bonus.

This posting is expected to remain open for at least seven days after it was posted on February 05, 2026.

Available benefits include medical, dental, vision, and prescription drug coverage; access to Health Coach from GE Vernova, a 24/7 nurse-based resource; and access to the Employee Assistance Program, providing 24/7 confidential assessment, counseling and referral services. Retirement benefits include the GE Vernova Retirement Savings Plan, a tax-advantaged 401(k) savings opportunity with company matching contributions and company retirement contributions, as well as access to Fidelity resources and financial planning consultants. Other benefits include tuition assistance, adoption assistance, paid parental leave, disability benefits, life insurance, 12 paid holidays, and permissive time off.

GE Vernova Inc. or its affiliates (collectively or individually, "GE Vernova") sponsor certain employee benefit plans or programs GE Vernova reserves the right to terminate, amend, suspend, replace, or modify its benefit plans and programs at any time and for any reason, in its sole discretion. No individual has a vested right to any benefit under a GE Vernova welfare benefit plan or program. This document does not create a contract of employment with any individual.