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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.
Job Responsibility:
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
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
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
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
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
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
Requirements:
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
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
What we offer:
Medical Plans, with PPO or HDHP options
Dental Plans, with buy-up option
Vision Plan
Life Insurance and Accidental Death & Dismemberment Plans, with buy-up options