Thermal Spray Industrialization & Process Development Engineering Technician

GE Vernova offers a hands-on role focused on industrializing and scaling thermal spray coating processes for gas turbine components. This position is based in Greenville, SC, and requires 100% on-site work.

About the role

As a member of the Process Industrialization team, you will develop, qualify, and industrialize thermal spray coating processes—primarily High Velocity Oxy-Fuel (HVOF) and Atmospheric Plasma Spray (APS)—for high-performance gas turbine components. The role blends practical coating cell work, metallographic analysis, machinery troubleshooting, and fixture/masking design to ensure repeatable, cost-effective production aligned with SQDC (Safety, Quality, Delivery, Cost) values. You will collaborate across R&D, manufacturing, quality, and customer teams in a high-volume manufacturing environment.

Responsibilities

• Industrialize and scale thermal spray coating processes to support GE Vernova’s volume expansion.
• Develop, qualify, and industrialize HVOF and APS processes from lab to full-scale production.
• Define and freeze critical thermal spray parameters to ensure repeatable processes meeting print and specification requirements.
• Operate and support thermal spray cells, including robotic spray programs, focusing on quality, cycle time, defect reduction, and waste minimization.
• Diagnose and resolve coating, equipment, and process issues to maintain long-term stability.
• Perform and interpret metallographic evaluations and mechanical testing to assess coating quality and lead root-cause analysis of defects.
• Execute shop work instructions and collaborate across engineering, operations, quality, and R&D teams.
• Design fixtures and masking for production coating applications (desired).

Requirements

• Combination of technical education, certifications, and significant hands-on thermal spray process development experience.
• 10+ years of hands-on thermal spray process development experience in manufacturing or industrialization environments.
• Proven experience developing new thermal spray coatings with expertise in plasma and/or HVOF parameters.
• Hands-on experience with HVOF and/or APS coating process development, qualification, and production support.
• Strong skills in coating microstructure evaluation and metallographic analysis (optical microscopy, image analysis).
• Excellent written and verbal communication skills; ability to work in multi-group environments toward shared goals.
• Ability to work on-site in a manufacturing environment, including off-shift or flexible schedules as required by project timelines.
• Expertise working with Fanuc Robot.

Desired Qualifications

• 15+ years of hands-on thermal spray process development experience in manufacturing and project environments (HVOF or APS).
• Experience with MCrAlY bond coats and TBC ceramic topcoats (e.g., YSZ).
• Gas turbine or aerospace coatings qualification experience or other high-performance industrial coating applications.
• Knowledge of blasting, masking, heat treatment, and post-processing of coated parts.

Pay

For candidates applying to this U.S.-based position, the pay range is $76,300–$114,400 annually. The company pays a geographic differential of 110%, 120%, or 130% of salary in certain areas. Pay may be influenced by experience, education, and skill set. Bonus eligibility includes a discretionary annual bonus.

Benefits

• Medical, dental, vision, and prescription drug coverage.
• Access to Health Coach (24/7 nurse-based resource) and Employee Assistance Program (confidential assessment, counseling, and referral services).
• Retirement Savings Plan (401(k)) with company matching and retirement contributions, plus Fidelity resources and financial planning consultants.
• Tuition assistance and adoption assistance.
• Paid parental leave, disability benefits, life insurance, 12 paid holidays, and permissive time off.

Relocation

Relocation assistance is provided for this role.

This role requires access to U.S. export-controlled information. Final offers are contingent on obtaining authorization for access from the U.S. Government.