Senior Aerospace Casting Engineer

The Senior Aerospace Casting Engineer is responsible for leading and supporting investment casting processes for turbine airfoil components.

This role provides technical ownership of Directional Solidification (DS), Single Crystal (SX), and Equiaxed (EQ) casting processes, ensuring robust, capable, and compliant manufacturing operations aligned with aerospace OEM requirements.

The position requires strong expertise in metallurgical processing, solidification science, and foundry operations, with the ability to drive technical excellence, continuous improvement, and production stability.

Due to government regulation only US persons (U.S.

citizen, U.S.

naturalized citizen, U.S.

permanent resident, holder of U.S.

approved political asylee or refugee status) may be considered for this role.



* Serve as the subject‑matter expert for DS, SX, and EQ turbine airfoil solidification science, governing CTQs, solidification modeling, and high‑fidelity process controls.


* Architect and optimize thermal profiles, withdrawal strategies, mold design parameters, alloy chemistries, and shell systems to achieve defect‑free, orientation‑controlled microstructures.


* Lead complex troubleshooting of casting anomalies—freckles, stray grains, recrystallization, porosity, grain misorientation—leveraging Laue diffraction, advanced metallography, and NDT interpretation.


* Drive development, qualification, and launch of new turbine airfoil casting processes, tooling, and ceramic systems, ensuring robust manufacturability and compliance with customer specifications.


* Direct structured root‑cause investigations using formal methodologies (DMAIC, 8D, PFMEA) and implement high‑impact corrective/preventive actions to improve yield, stability, and throughput.


* Serve as the technical interface to customer engineering teams and provide expert mentorship to internal engineers, fostering capability growth and alignment with program and quality requirements.

Education & Experience:


* Bachelor’s degree in Metallurgical, Materials, Mechanical Engineering, or related field.

Master’s degree is preferred.


* 10+ years of experience in aerospace investment casting or turbine airfoil/component manufacturing


* Deep expertise in DS, SX, and EQ casting processes


* Proven ability to troubleshoot complex metallurgical and process‑control issues


* Experience with aerospace quality systems (AS9100, NADCAP)


* Strong technical leadership and ownership mindset


* Data‑driven decision‑maker with strong analytical and problem‑solving skills


* Clear, concise technical communicator; able to influence across teams


* Thrives in fast‑paced, high‑precision manufacturing environments

Preferred skills


* Experience with nickel‑based superalloys (René, CMSX, PWA families)


* Proficiency with Laue X‑ray diffraction and advanced metallography


* Lean or Six Sigma certification