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Senior Staff Scientist - Large Scale Additive Manufacturing

Date: Jul 27, 2021

Location: Knoxville, TN, US, 37932

Company: Oak Ridge National Laboratory

Requisition Id 4272 



We are seeking a Senior Staff Scientist who will focus on the processing and process development of metals for wire feed large scale metaling additive manufacturing (AM) for energy applications. Research will focus on applying fundamental scientific and technology knowledge from welding to solve open problems in large scale metal AM. This position resides in the Deposition Science and Technology Group in the Manufacturing Science Division, Energy Sciences Technology Directorate (ESTD) at the Oak Ridge National Laboratory (ORNL).



As part of our research team, you will be among team members based at the Manufacturing Demonstration Facility (MDF), the Department of Energy’s (DOE’s) first facility established to provide affordable and convenient access to R&D expertise, facilities, and tools to facilitate rapid adoption of advanced manufacturing technologies including additive manufacturing of alloys and composites. To improve the capabilities of this facility with large scale additive manufacturing, you will lead the effort to enhance and grow the large-scale programs for strategic energy applications. You will perform the fundamental research to improve materials selection and processing through wire arc and laser additive manufacturing to drive process deposition efficiency enhancements, material quality improvements through mechanical performance improvement, and further increase the economics of the processes through feedstock developments. Additional focus will be on the development of hybrid materials, dissimilar metal joints, and structures of graded metal compositions. Further, the candidate will collaborate with interdisciplinary staff for enhancing the processing routes or to propose improvement/alternative processing for the deposition of metals for large scale AM components.


Major Duties/Responsibilities: 

•Provide strategic scientific and technical leadership in the area of materials for large scale additive manufacturing.

•Contribute to new and ongoing research in wire arc and laser wire feed large scale additive manufacturing.

•Contribute to novel solutions to problems of national interest, and to the research and development necessary for the deployable implementation of those solutions.

•Represent ORNL’s scientific capabilities through participation on national scientific committees, leadership in professional organizations, and presentation of research concepts and accomplishments to national audiences at all levels (scientific organizations, collaborators, funding agencies, etc.).

•Work within ORNL teams to develop requirements and proposals, conduct research, and produce working prototypes for demonstration.

•Contribute to peer-reviewed papers, technical reports, and proposals for internal and external release, and represent ORNL science and technology at conferences and workshops.

•Contribute to invention disclosures, transition of ORNL research to commercial use, market research, and industry/government activities to enable ORNL science and technology use in practice


Basic Qualifications:

•A Ph.D. degree in mechanical engineering, materials science, weld engineering, or a directly related field

•A minimum of six years of experience in R&D and scientific leadership


  Preferred Qualifications:

  • A minimum of 12 years of experience in R&D and scientific leadership
  • Excellent record of productive and creative research as demonstrated by publications in peer-reviewed journals
  • Experience with dissimilar metal joining and/or functionally graded metals
  • Excellent written and oral communication skills and the ability to communicate to an international, scientific audience
  • Motivated self-starter with the ability to work independently and to participate creatively in collaborative teams across the laboratory 
  • Ability to function well in a fast-paced research environment, set priorities to accomplish multiple tasks within deadlines, and adapt to ever changing needs



This position will remain open for a minimum of 5 days after which it will close when a qualified candidate is identified and/or hired.

We accept Word (.doc, .docx), Adobe (unsecured .pdf), Rich Text Format (.rtf), and HTML (.htm, .html) up to 5MB in size. Resumes from third party vendors will not be accepted; these resumes will be deleted and the candidates submitted will not be considered for employment.

If you have trouble applying for a position, please email

ORNL is an equal opportunity employer. All qualified applicants, including individuals with disabilities and protected veterans, are encouraged to apply.  UT-Battelle is an E-Verify employer.

Nearest Major Market: Knoxville