Principal Casting Engineer

Job Purpose

Key Responsibilities

• Guide technical decisions on casting equipment, tooling, processes, and metallurgy for aero-engine component production.
• Act as technical authority on investment casting for turbine airfoils and other aero-engine castings.
• Guide selection and specification of vacuum induction melting, DS/SX, shell room, wax injection, NDT, and HIP equipment.
• Define tooling strategies for wax dies, ceramic cores, shell systems, grain selectors, starter blocks, and structural castings.
• Lead alloy selection, gating and feeding design, solidification modelling, and resolution of porosity, freckles, recrystallization, and grain defects.
• Support partner technical evaluation alongside the Manager.
• Develop process specifications, qualification plans, and technical training curriculum.
• Mentor junior engineers as the in-house casting metallurgy and process expert.

Required Experience

• 15+ years of hands-on experience in investment casting of aero-engine components.
• Deep expertise in airfoil casting using equiaxed, directionally solidified, or single-crystal processes, or in large structural aero-engine castings.
• Strong knowledge of nickel-based superalloys including CMSX-4, René N5, MAR-M247, and IN738, plus associated heat treatment.
• Hands-on experience with shell systems, ceramic cores, and grain control techniques.
• Familiarity with ProCAST, MAGMASOFT, or similar simulation tools.
• Background at a Tier 1 caster or OEM in-house casting facility.
• Engineering degree in Materials Science, Metallurgy, or a related discipline.
• PhD or equivalent technical depth is strongly preferred.

Advantageous Qualifications

• Published work, patents, or recognised industry standing in aero-engine casting is advantageous.
• Prior experience commissioning a greenfield casting facility is advantageous.

Relocation

• Relocation support to Abu Dhabi is available for exceptional international candidates.