Research Scientist (Cold Spray) - Mechanical, Aerospace, & Biomedical Engineering, Tickle College of Engineering: UTK

The Research Scientist will advance cold spray deposition science and technology, supporting the Department of Defense-funded initiatives in areas such as structural repair and expeditionary manufacturing. The position involves process development, material compatibility studies, performance validation, and integration of CSAM components into defense platforms. This role will also represent the University of Tennessee in collaborations with government and industry partners, mentor students, manage cold spray infrastructure, and contribute to the technical leadership of the UT Defense Research Center. This is a grant-funded position and is contingent upon the continued funding of the grant. 

The Research Scientist will be responsible for the following:

• Designing and executing experiments to evaluate cold spray deposition performance across metals, polymers, spatially graded, and hybrid material systems.
• Optimizing spray parameters for both high- and low-pressure systems to achieve robust bonding, dimensional accuracy, and repeatability.
• Characterizing as-sprayed materials and build quality using microscopy, profilometry, ultrasonic inspection, and mechanical evaluation.
• Studying particle-substrate interactions, critical velocity behavior, and deposition efficiency across various feedstock types and substrates.
• Conducting post-process evaluations to assess performance metrics including adhesion, wear resistance, fatigue, and environmental durability.
• Implementing and refining in-situ monitoring tools to measure particle velocity, substrate temperature, and deposition rate.
• Developing models and data-driven methods to correlate process parameters with deposition quality and performance.
• Support efforts in developing process qualification pathways and performance benchmarks for CSAM parts.
• Mentoring students, technicians, and DoD collaborators in cold spray system operation, safety, experimental design, and data analysis.
• Providing technical instruction on cold spray system capabilities, maintenance, and safe laboratory practices.
• Overseeing the operation and maintenance of cold spray systems and supporting characterization tools.
• Leading and supporting manufacturing demonstrations and development efforts with DoD and industry partners.
• Hosting facility tours, technical briefings, and collaborative engagements with external stakeholders and sponsors.

Required Qualifications:

• Education: Master’s Degree in Mechanical Engineering or job-related Engineering disciplines
• Experience: 3 years of experience in cold spray additive manufacturing and repair
• Knowledge, Skills, Abilities: Knowledge of operation and ability to use cold spray for part production, repair, and experiments for model development. Ability to use and interpret results of measurements performed during operations and post characterization. Technical writing skills for proposals, reports, and manuscript preparation. Strong interpersonal and collaborative relationship skills are needed for success in this role. 

Applicants must be legally authorized to work in the United States on a full-time basis without need now or in the future for sponsorship for employment visa status.

Preferred Qualifications:

• Education: Doctoral Degree in Mechanical Engineering or job-related Engineering disciplines 
• Experience: 1 year or more experience in CNC machining. 1 year or more experience with structured light scanners, coordinate measuring machines, optical profilometers.1 year or more experience with other additive manufacturing processes for metals, polymers, or ceramics.
• Knowledge, Skills, Abilities: Knowledge and operation of materials characterization techniques such as optical microscopy, SEM/EDS, EBSD, XRD, microhardness testing, and mechanical evaluation (tensile, compression, fatigue). Knowledge of operation and ability to use CNC machining for part production and experiments. Knowledge of operation and ability to use wire electrical discharge machining for part production. Knowledge of operation and ability to use and interpret results of measurements performed using structured light scanners, coordinate measuring machines, optical profilometers. Knowledge of operation and ability to use of other additive manufacturing techniques an