Job description

Overview At PNNL, our core capabilities are divided among major departments that we refer to as Directorates within the Lab, focused on a specific area of scientific research or other function, with its own leadership team and dedicated budget. Our Science & Technology directorates include National Security, Earth and Biological Sciences, Physical and Computational Sciences, and Energy and Environment. In addition, we have an Environmental Molecular Sciences Laboratory, a Department of Energy, Office of Science user facility housed on the PNNL campus. The Energy and Environment Directorate delivers science and technology solutions for the nation’s biggest energy and environmental challenges. Our more than 1,700 staff support the Department of Energy (DOE), delivering on key DOE mission areas including: modernizing our nation’s power grid to maintain a reliable, affordable, secure, and resilient electricity delivery infrastructure; research, development, validation, and effective utilization of renewable energy and efficiency technologies that improve the affordability, reliability, resiliency, and security of the American energy system; and resolving complex issues in nuclear science, energy, and environmental management. The Energy Processes and Materials Division , part of the Energy and Environment Directorate, creates and delivers real world solutions that support the Department of Energy’s goals for national energy security. We deliver new technologies that connect fundamental science to applications in areas such as energy storage, advanced materials manufacturing, applied catalysis, advanced separations, biomass conversions, carbon capture and utilization , and hydrogen production and storage. We employ a systems perspective that includes discovery, technology development, and scale-up as well as economic, regulatory, and market acceptance issues necessary for successful technology commercialization. Responsibilities Our expert staff provide multi-disciplinary solutions to complex energy and environmental issues. Key capabilities include science (chemical and mechanical). We employ a systems perspective that includes discovery technology development and scale-up, as well as economic, regulatory, and market acceptance issues necessary for successful technology commercialization. The Energy Processes & Materials (EP&M) Division focuses on three mission contributions at PNNL: Energy Resiliency, Electricity Infrastructure, & Energy Efficiency and Renewable Energy. The Applied Materials and Manufacturing (AMM) Group in EP&M Division at PNNL is seeking a Mechanical Engineer to lead experimental process development for power systems materials such as conductors and magnets. The position will develop operating conditions and process envelopes for power system materials with enhanced performance enabled by advanced manufacturing platforms such as shear/friction extrusion, friction stir welding/forging, friction stir additive manufacturing and cold spray. The engineer will collaborate with process engineers, manufacturing experts and materials researchers to translate experimental findings into documented operating recommendations based on material. The successful candidate will build a technical specialization in thermomechanical process development and contribute to research planning and publications. Key Responsibilities: • Design experiments to evaluate operating parameters, tooling designs, manufacturing configurations and feedstock conditions using statistical experimental design where appropriate. • Design tooling using CAD and coordinate their development with external or internal manufacturing facilities/vendors. • Investigate process stability, and product quality to develop frameworks for operational controls. • Develop process windows and document the evidence, limitations, and repeatability supporting recommended conditions. • Work with process engineers to design and deploy digital twin technologies that integrate physics-based models, real-time operational data, and advanced analytics to improve manufacturing performance and resilience. • Communicate results through technical summaries, project reports, conference presentations, journal articles and other technical manuscripts. • Designs, analyzes, manufactures, and maintains mechanical systems. • Designs, produces, and operates machinery. • Applies principles of engineering, physics, and materials science as well as an understanding of core areas including mechanics, kinematics, thermodynamics, materials science, structural analysis, and electricity along with tools like computer-aided design and product lifecycle management to design and analyze manufacturing plants, industrial equipment, and machinery; heating and cooling systems; transport systems; aircraft; watercraft; robotics; medical devices; weapons; and others. • Researches, plans, designs, and develops mechanical products and systems such as instruments, controls, robots, engines, machines, and mechanical, thermal hydraulic, or heat transfer systems for production, transmission, measurement, and use of energy. • Designs, develops, and implements numerical methods for Computational Fluid Dynamics or Structural Mechanics analyses using advanced programming techniques. • Conducts research and evaluation of technologies and methods for efficient operation and control of energy, water, and other resource use in buildings and connected systems. • Develops, analyzes, and tests technologies, facilitating their adoption and integration in commercial and residential buildings. • Conducts state-of-art whole building energy simulation modeling at a large scale to address building type and climate zone variation across the country. • Conducts engineering and economic analysis to advance building energy codes and appliance standards. • Develops and applies building performance evaluation methods and field studies to identify building envelope, systems, and operational efficiency measures. • Develops and applies meter and building automation system data measurement and monitoring methods to understand and optimize building performance. • Optimizes the performance of building control systems with architectures systems integration and algorithms for maintaining the specific process within a desired range. • Evaluates the impact of statutory and regulatory requirements on buildings and energy-using equipment. Qualifications Minimum Qualifications: • BS/BA and 2 years of relevant experience -OR- • MS/MA -OR- • PhD • Relevant experience includes friction stir welding, metal extrusion, metal drawing, rolling, friction extrusion, or related solid-phase processing technologies • Experience with mechanical design, tooling design and CAD. Preferred Qualifications: • Research experience in experimental manufacturing, metal forming, or thermomechanical processing, with particular experience with shear-assisted process extrusion. • Experience planning controlled experiments and analyzing quantitative process and materials data. • Familiarity with instrumentation, process data acquisition, and evaluation of experimental uncertainty. • Ability to document technical findings and collaborate across engineering, materials science, and operations. • Experience with mechanical design, tooling design and CAD. • Hands-on experience commissioning or developing processes on research or pilot equipment. • Publications or demonstrated research contributions in manufacturing process development. • Developing interns, post bachelor's, post masters, and post doctorates. Hazardous Working Conditions/Environment Not Applicable Testing Designated Position This is not a Testing Designated Position (TDP). About PNNL Pacific Northwest National Laboratory (PNNL) is a world-class research institution powered by a highly educated, diverse workforce committed to the values of Integrity, Creativity, Collaboration, Impact, and Courage. Every year, scores of dynamic, driven people come to PNNL to work with renowned researchers on meaningful science, innovations and outcomes for the U.S. Department of Energy and other sponsors; here is your chance to be one of them! At PNNL, you will find an exciting research environment and excellent benefits including health insurance, and flexible work schedules. PNNL is located in eastern Washington State—the dry side of Washington known for its stellar outdoor recreation and affordable cost of living. The Lab’s campus is only a 45-minute flight (or ~3 hour drive) from Seattle or Portland, and is serviced by the convenient PSC airport, connected to 8 major hubs. Commitment to Excellence and Equal Employment Opportunity Our laboratory is committed to fostering a work environment where all individuals are treated with fairness and respect while solving critical challenges in fundamental sciences, national security, and energy resiliency. We are an Equal Employment Opportunity employer. Pacific Northwest National Laboratory (PNNL) is an Equal Opportunity Employer. PNNL considers all applicants for employment without regard to race, religion, color, sex, national origin, age, disability, genetic information (including family medical history), protected veteran status, and any other status or characteristic protected by federal, state, and/or local laws. We are committed to providing reasonable accommodations for individuals with disabilities and disabled veterans in our job application procedures and in employment. If you need assistance or an accommodation due to a disability, contact us at careers@pnnl.gov . Drug Free Workplace PNNL is committed to a drug-free workplace supported by Workplace Substance Abuse Program (WSAP) and complies with federal laws prohibiting the possession and use of illegal drugs. If you are offered employment at PNNL, you must pass a drug test prior to commencing employment. PNNL complies with federal law regarding illegal drug use. Under federal law, marijuana remains an illegal drug. If you test positive for any illegal controlled substance, including marijuana, your offer of employment will be withdrawn. Security, Credentialing, and Eligibility Requirements As a national laboratory, PNNL is responsible for adhering to the Homeland Security Presidential Directive 12 (HSPD-12) and Department of Energy (DOE) Order 473.1A, which require new employees to obtain and maintain a HSPD-12 Personal Identify Verification (PIV) Credential. To obtain this credential, new employees must successfully complete the applicable tier of federal background investigation post hire and receive a favorable federal adjudication. The tier of federal background investigation will be determined by job duties and national security or public trust responsibilities associated with the job. All tiers of investigation include a declaration of illegal drug activities, including use, supply, possession, or manufacture within the last 1 to 7 years (depending on the applicable tier of investigation). Illegal drug activities include marijuana and cannabis derivatives, which are still considered illegal under federal law, regardless of state laws. For foreign national candidates: If you have not resided in the U.S. for three consecutive years, you are not eligible for the PIV credential and instead will need to obtain a favorable Local Site Specific Only (LSSO) Federal risk determination to maintain employment. Once you meet the three-year residency requirement thereafter, you will be required to obtain a PIV credential to maintain employment. The tier of federal background investigation required to obtain the PIV credential will be determined by job duties at the time you become eligible for the PIV credential. Mandatory Requirements Please be aware that the Department of Energy (DOE) prohibits DOE employees and contractors from having any affiliation with the foreign government of a country DOE has identified as a “country of risk” without explicit approval by DOE and Battelle. If you are offered a position at PNNL and currently have any affiliation with the government of one of these countries, you will be required to disclose this information and recuse yourself of that affiliation or receive approval from DOE and Battelle prior to your first day of employment. Rockstar Rewards Employees and their families are offered medical insurance, dental insurance, vision insurance, robust telehealth care options, several mental health benefits, free wellness coaching, health savings account, flexible spending accounts, basic life insurance, disability insurance*, employee assistance program, business travel insurance, tuition assistance, relocation, backup childcare, legal benefits, supplemental parental bonding leave, surrogacy and adoption assistance, and fertility support. Employees are automatically enrolled in our company-funded pension plan* and may enroll in our 401 (k) savings plan with company match*. Employees may accrue up to 120 vacation hours per year and may receive ten paid holidays per year. * Research Associates excluded. **All benefits are dependent upon eligibility. Click Here For Rockstar Rewards Notice to Applicants PNNL lists the full pay range for the position in the job posting. Starting pay is calculated from the minimum of the pay range and actual placement in the range is determined based on an individual’s relevant job-related skills, qualifications, and experience. This approach is applicable to all positions, with the exception of positions governed by collective bargaining agreements and certain limited-term positions which have specific pay rules. As part of our commitment to fair compensation practices, we do not ask for or consider current or past salaries in making compensation offers at hire. Instead, our compensation offers are determined by the specific requirements of the position, prevailing market trends, applicable collective bargaining agreements, pay equity for the position type, and individual qualifications and skills relevant to the performance of the position. Minimum Salary USD $89,300.00/Yr. Maximum Salary USD $131,200.00/Yr.

Requirements

Must-haves

The successful candidate will build a technical specialization in thermomechanical process development and contribute to research planning and publications.
Design experiments to evaluate operating parameters, tooling designs, manufacturing configurations and feedstock conditions using statistical experimental design where appropriate.
Design tooling using CAD and coordinate their development with external or internal manufacturing facilities/vendors.
Investigate process stability, and product quality to develop frameworks for operational controls.
Develop process windows and document the evidence, limitations, and repeatability supporting recommended conditions.
Work with process engineers to design and deploy digital twin technologies that integrate physics-based models, real-time operational data, and advanced analytics to improve manufacturing performance and resilience.
Communicate results through technical summaries, project reports, conference presentations, journal articles and other technical manuscripts.
Designs, analyzes, manufactures, and maintains mechanical systems.
Designs, produces, and operates machinery.
Designs, develops, and implements numerical methods for Computational Fluid Dynamics or Structural Mechanics analyses using advanced programming techniques.
Conducts research and evaluation of technologies and methods for efficient operation and control of energy, water, and other resource use in buildings and connected systems.
Develops, analyzes, and tests technologies, facilitating their adoption and integration in commercial and residential buildings.

Nice-to-haves

Research experience in experimental manufacturing, metal forming, or thermomechanical processing, with particular experience with shear-assisted process extrusion.
Experience planning controlled experiments and analyzing quantitative process and materials data.
Familiarity with instrumentation, process data acquisition, and evaluation of experimental uncertainty.
Ability to document technical findings and collaborate across engineering, materials science, and operations.
Experience with mechanical design, tooling design and CAD.
Hands-on experience commissioning or developing processes on research or pilot equipment.
Publications or demonstrated research contributions in manufacturing process development.
Developing interns, post bachelor's, post masters, and post doctorates.
Hazardous Working Conditions/Environment
Not Applicable
Testing Designated Position
This is not a Testing Designated Position (TDP).

Application prep

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Effort: medium

Benefits

Benefits detected in the listing.

Health Insurance

Dental

Vision

Wellness