Auto req ID: 54007
Title: Sr Engineer Materials - Aluminum Systems
Job Function: Engineering
Location: PDC
Workplace Category:Onsite
Company: Harley-Davidson Motor Company
Full or Part-Time: Full Time
Shift: SHIFT1 At Harley-Davidson, we are building more than machines. It's our passion and commitment to continue the evolution of this storied brand, and heighten the desirability of the Harley-Davidson experience. To keep building our legend and leading our industry through innovation, evolution, and emotion we need the best and brightest talent. We stand for the timeless pursuit of adventure. Freedom for the soul. Are you ready to join us?
The Harley-Davidson Motor Company Product Development Center (PDC) located in Wauwatosa, WI is home to the mantra - You dream it. We build it. Join our team as a Sr Engineer Materials - Aluminum Systems.
Job SummaryThe Senior Materials Engineer is responsible for supporting the Product Development Process by providing deep technical expertise in aluminum materials, with a strong emphasis on cast aluminum components and systems. This role partners with product development, manufacturing, and suppliers to ensure robust material selection, processing, and performance. The engineer leads material-related problem solving, including failure analysis and root cause investigations, with a focus on improving aluminum casting quality and reliability in motorcycle applications.
Job ResponsibilitiesCore Responsibilities:- The role requires strong applied knowledge of aluminum alloys, including how composition, microstructure, and processing influence performance in real-world applications. The engineer will guide material selection and design decisions based on component requirements, particularly for structural and cosmetic cast aluminum parts.
- A key expectation is expertise in aluminum casting processes such as high-pressure die casting, permanent mold casting, and sand casting, including an understanding of common defect modes, process controls, and quality risks. The engineer will work closely with suppliers and manufacturing teams to improve casting quality, resolve defects, and support process development.
- The position also includes technical leadership of failure analysis and root cause investigations related to aluminum components. This includes metallurgical evaluation, interpretation of lab results, and clear documentation of findings with actionable recommendations.
- The engineer will apply knowledge of heat treatment and thermal processing specific to aluminum alloys, including how these processes affect strength, durability, and dimensional stability. Familiarity with corrosion behavior and surface treatments for aluminum is also expected, particularly as it relates to product durability and appearance.
- In collaboration with design and validation teams, the engineer supports understanding of mechanical behavior, including fatigue performance, and how it relates to casting quality, defects, and service loading conditions.
- This role requires close cross-functional engagement, providing technical guidance to engineering teams, supporting supplier quality improvements, and ensuring alignment between design intent and manufacturing capability.
Laboratory & Analytical Capability- The candidate should be comfortable working with standard metallurgical and analytical tools to evaluate aluminum materials, including techniques such as optical emission spectroscopy, microscopy, and fractography. The ability to interpret results and connect laboratory findings to real-world component performance is essential. Candidate must be willing to perform preventive maintenance on lab equipment, plan for ordering necessary lab equipment, and keep track of budget expenses.
Leadership & Communication- This role serves as a technical advisor in aluminum materials, providing guidance across engineering teams and mentoring others as needed. The candidate must be able to communicate technical findings clearly and effectively to both technical and non-technical stakeholders.
Education RequirementsBachelor's Degree Required
Education SpecificationsBachelor's degree in Materials Engineering, Metallurgy, or a related field is required.
Experience RequirementsA minimum of five years of experience in materials engineering is required, with demonstrated hands-on experience in aluminum materials and casting processes, preferably in product development or manufacturing environments.
Applicants must be authorized to work in the United States.
The pay range shown represents the national average pay range for this role. Your pay may be more or less than the stated range and is dependent on your geographic location and level of experience.
We offer an inclusive compensation package for all full-time salaried employees including, but not limited to, annual bonus programs, health insurance benefits, a 401k program, onsite fitness centers and employee stores, employee discounts on products and accessories, and more. Learn more about Harley-Davidson here.
Applicants must be currently authorized to work in the United States.
Direct Reports: Yes
Travel Required: 0 - 10%
Pay Range: $93,400 - $145,000 Visa Sponsorship: This position is not eligible for visa sponsorship or visa transfer
Relocation: This position is eligible for domestic relocation assistance (within posted country) 
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