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Casting Process Engineer

Associate | Full-time
Engineering | livermore, CA | 03/16/2023

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Company Description

Join us and make YOUR mark on the World!

Are you interested in joining some of the brightest talent in the world to strengthen the United States’ security? Come join Lawrence Livermore National Laboratory (LLNL) where our employees apply their expertise to create solutions for BIG ideas that make our world a better place.

We are committed to a diverse and equitable workforce with an inclusive culture that values and celebrates the diversity of our people, talents, ideas, experiences, and perspectives. This is important for continued success of the Laboratory’s mission.

Pay Range

$123,960 - $166,992 Annually for the SES.2 level
$148,650 - $200,328 Annually for the SES.3 level

Please note that the pay range information is a general guideline only. Many factors are taken into consideration when setting starting pay including education, experience, the external labor market, and internal equity.


Job Description

We have an opening for a Casting Process Engineer supporting stockpile stewardship of nuclear materials working in the Nuclear Materials Program. You will work with technicians, designers, and scientists to develop robust casting processes for nuclear materials. You will perform a range of moderate to complex research and development in the area of casting operations, process parameter optimization, mold design, furnace design, and casting modeling. Some of this work will be performed on radioactive materials in an inert-atmosphere glovebox within a high-hazard nuclear facility. This position is in the Defense Technologies Engineering Division (DTED), within the Engineering Directorate. DTED provides support to Weapons and Complex Integration (WCI) Programs.

This position will be filled at either level based on knowledge and related experience as assessed by the hiring team. Additional job responsibilities (outlined below) will be assigned if hired at the higher level.

In this role you will

  • Perform moderate to complex research and development related to the casting of nuclear materials.
  • Model and perform simulations of multi-phase casting operations.
  • Participate to the expansion of casting capabilities by procuring, installing, maintaining, and upgrading instruments, contributing to safety documentation, writing operational procedures, training operators, and implementing process improvements.
  • Prepare written analyses, verbal briefings, and other products that capture and communicate research results.
  • Present progress and findings to sponsors and customers.
  • Complete training to become a Certified Fissile Material Handler and maintain status.
  • Maintain progress on assigned project(s) while managing priorities.
  • Perform other duties as assigned.

Additional job responsibilities, at the SES.3 level

  • Perform advanced process development of casting components and precision engineering fabrication of complex experimental components.
  • Serve as the primary technical contact on specific projects for LLNL customers.
  • Provide advanced technical solutions to complex problems that may not be well defined.
  • Lead projects with minimal direction.


  • Ability to secure and maintain a U.S. DOE Q-level security clearance which requires U.S. Citizenship.
  • Bachelor’s degree in Materials Science, Materials Engineering, Metallurgy, Nuclear Engineering, Chemical Engineering, Mechanical Engineering or a related field, or the equivalent combination of education and related experience.
  • Comprehensive knowledge of two or more of the following: materials science, solidification, phase transformations, fluid dynamics, and heat transfer.
  • Ability and willingness to work with hazardous materials.
  • Experience operating computers to collect, analyze, and document scientific results.
  • Ability to work independently and as a member of a team.
  • Proficient verbal and written communication skills necessary to interact with a diverse set of scientists, engineers, and other technical and administrative staff within a collaborative research and development environment.

Additional qualifications at the SES.3 level

  • Experience modeling processes involving fluid dynamics and/or heat transfer using software such as ANSYS, COMSOL, Flow3D, ProCAST, etc.
  • Experience with process controls and software such as LabView or Factory Talk along with data analysis using MATLAB, Python, etc.
  • Experience related to foundry and/or metals heat treatment operations.
  • Advanced knowledge of materials science concepts, phase transformations, alloying, solidification, and microstructure-properties relationships, and solidification, phase transformations, fluid dynamics, and heat transfer.

Qualifications We Desire

  • Master’s degree or PhD in Materials Science, Materials Engineering, Metallurgy, Nuclear Engineering, Chemical Engineering, Mechanical Engineering or a related field.
  • Experience working in gloveboxes. Experience handling radioactive, pyrophoric, or other hazardous materials.
  • Experience troubleshooting and maintaining instruments.
  • Experience designing and fabricating simple fixtures and components.

Additional Information

All your information will be kept confidential according to EEO guidelines.




Position Information

This is a Career Indefinite position, open to Lab employees and external candidates.

Why Lawrence Livermore National Laboratory?

Security Clearance

This position requires a Department of Energy (DOE) Q-level clearance.  If you are selected, we will initiate a Federal background investigation to determine if you meet eligibility requirements for access to classified information or matter. Also, all L or Q cleared employees are subject to random drug testing.  Q-level clearance requires U.S. citizenship. 

Pre-Employment Drug Test

External applicant(s) selected for this position must pass a post-offer, pre-employment drug test. This includes testing for use of marijuana as Federal Law applies to us as a Federal Contractor.

Pre-Placement Medical Exam

A job related pre-placement medical examination may be required.

Equal Employment Opportunity

We are an equal opportunity employer that is committed to providing all with a work environment free of discrimination and harassment. All qualified applicants will receive consideration for employment without regard to race, color, religion, marital status, national origin, ancestry, sex, sexual orientation, gender identity, disability, medical condition, pregnancy, protected veteran status, age, citizenship, or any other characteristic protected by applicable laws.

We invite you to review the Equal Employment Opportunity posters which include EEO is the Law and Pay Transparency Nondiscrimination Provision.

Reasonable Accommodation

Our goal is to create an accessible and inclusive experience for all candidates applying and interviewing at the Laboratory.  If you need a reasonable accommodation during the application or the recruiting process, please use our online form to submit a request. 

California Privacy Notice

The California Consumer Privacy Act (CCPA) grants privacy rights to all California residents. The law also entitles job applicants, employees, and non-employee workers to be notified of what personal information LLNL collects and for what purpose. The Employee Privacy Notice can be accessed here.

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