Failure Analysis Engineer, Metallurgy & Corrosion

What to Expect

Tesla is seeking a Failure Analysis Engineer with a foundation in metallurgy and corrosion to join our Analytical Services team in the Failure Analysis Lab. The team's mission is to identify root causes and contributing factors to enhance Tesla's products, working closely with diverse engineering groups.

You will handle a broad range of Vehicle and Energy systems, from the current fleet to emerging products. You will support root cause investigations for electromechanical components, low voltage and high voltage devices, contributing to reliability and performance in electric vehicles. This hands‑on role involves materials characterization and failure analysis to drive improvements in design and manufacturing, aligning with Tesla's mission to accelerate the world's transition to sustainable energy.

• Conduct hands‑on root cause investigations of material and component failures in electromechanical systems, focusing on metallurgy and corrosion mechanisms
• Perform materials characterization using techniques such as metallography, SEM/EDS, optical microscopy, hardness testing, and non‑destructive evaluations
• Analyze failure modes in metallic components, including alloys in low voltage and high voltage devices, identifying defects, microstructural issues, or environmental degradation
• Interpret test data to determine manufacturing, design, or service‑related causes
• Develop and execute hands‑on testing protocols, including destructive and non‑destructive methods, to replicate failures and validate material performance
• Prepare technical reports and present findings to engineering, quality, and production teams
• Collaborate with cross‑functional teams to recommend material or process changes and prevent recurrence
• Manage lab workflows and ensure equipment maintenance and safety compliance

• Masters or PhD in Metallurgy, Materials Science and Engineering, Mechanical Engineering, or related field, or equivalent experience
• 3+ years in failure analysis or materials testing
• Strong knowledge of metallurgical principles, including phase transformations, alloy behavior, fracture mechanics, corrosion mechanisms, and high‑temperature material properties
• Hands‑on proficiency with analytical tools such as SEM, EDS, FIB, XRD, tensile testing, fractography, and corrosion testing (e.g., ASTM standards)
• Familiarity with electromechanical components and devices in automotive or high‑performance applications
• Problem‑solving skills and ability to work in dynamic teams
• Strong verbal and written communication skills for technical reporting
• Experience with welding or joining processes
• Knowledge of standards like ASTM for testing and analysis
• Familiarity with simulation tools for Finite Element Analysis (FEA) for modeling stress, corrosion, or failure scenarios

Along with competitive pay, as a full‑time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans – plan options with $0 payroll deduction
• Family‑building, fertility, adoption and surrogacy benefits
• Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
• Company paid (Health Savings Accounts) HSA Contribution when enrolled in the high‑deductible medical plan with HSA
• Healthcare and Dependent Care Flexible Spending Accounts (FSA)
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
• Company paid Basic Life, AD&D
• Short‑term and long‑term disability insurance (90 day waiting period)
• Employee Assistance Program
• Sick and vacation time (flex time for salary positions, accrued hours for hourly positions), and paid holidays
• Back‑up childcare and parenting support resources
• Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
• Weight loss and tobacco cessation programs
• Tesla Babies program
• Commuter benefits
• Employee discounts and perks program

$84,000 - $192,000 annual salary + cash and stock awards + benefits

Pay offered may vary depending on multiple individualized factors, including market location, job‑related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.