Requirements
Requires 15+ years of hands-on experience in investment casting of aero-engine components, with deep expertise in airfoil casting and/or large structural aero-engine castings. Strong working knowledge of nickel-based superalloys, associated heat treatment, shell systems, ceramic cores, and grain control techniques is essential. Familiarity with simulation tools like ProCAST or MAGMASOFT is also required.
Description
Job Title: Principal Engineer, CastingsLocation: UAEReporting to: Manager, Castings & ForgingsJob Purpose:A leading aerospace and propulsion technology company is seeking a Principal Engineer, Castings to serve as the senior technical authority for casting equipment, tooling, processes, and metallurgy related to aero-engine component production. This role will provide expert guidance across investment casting operations, support technical evaluations, develop process specifications and qualification plans, and mentor engineering teams while driving technical excellence in aero-engine casting technologies.Key Responsibilities:Serve as the senior subject-matter expert guiding all technical decisions on casting equipment, tooling, processes, and metallurgy for aero-engine component production.Act as the technical authority on investment casting processes for turbine airfoils and other aero-engine castingsGuide selection and specification of casting equipment (vacuum induction melting furnaces, DS/SX furnaces, shell rooms, wax injection, NDT, HIP, etc.)Define tooling strategies — wax dies, ceramic core tooling, shell systems, grain selectors, starter blocks, large structural casting toolingProvide technical leadership on alloy selection, gating and feeding design, solidification modelling, and defect resolution (porosity, freckles, recrystallization, grain defects)Support partner technical evaluation alongside the ManagerDevelop process specifications, qualification plans, and the technical training curriculum for the local teamMentor junior engineers and act as the in-house go-to expert on casting metallurgy and processRequired Experience:15+ years of hands-on experience in investment casting of aero-engine componentsDeep expertise in airfoil casting (equiaxed, DS, and/or SX) and/or large structural aero-engine castingsStrong working knowledge of nickel-based superalloys (CMSX-4, René N5, MAR-M247, IN738, etc.) and associated heat treatmentHands-on experience with shell systems, ceramic cores, and grain control techniquesFamiliarity with simulation tools (ProCAST, MAGMASOFT, or similar)Background at a Tier 1 caster or OEM in-house casting facilityEngineering degree in Materials Science, Metallurgy, or related; PhD or equivalent technical depth strongly preferredAdvantageous:Published work, patents, or recognised industry standing in aero-engine castingPrior experience commissioning a greenfield casting facilityRelocation support to Abu Dhabi is available for exceptional international candidates.