Senior Casting Process Engineer

2 weeks ago

Dayton, Ohio, United States ASM International Full time
Job Overview
The Senior Casting Process Engineer will spearhead the innovation and enhancement of advanced manufacturing and casting techniques for next-generation high-pressure turbine (HPT) airfoils. This role encompasses the entire spectrum from ideation to the implementation of materials, products, and processes for pilot production lines. The application of scientific and engineering principles is essential to validate the technical viability of new ideas and to address manufacturing and design challenges.

Key Responsibilities
- Drive advancements in turbine airfoil design, materials, additive manufacturing techniques, and casting methodologies.
- Execute Technology Readiness Level (TRL) risk mitigation plans, demonstrating critical factors and parameters for process capability and control.
- Document insights and lessons learned from newly established procedures and designs.
- Ensure adherence to Safety, Quality, Delivery, and Cost (SQDC) metrics while employing scientific methodologies, engineering tools, and lean practices.
- Collaborate proactively across functions to tackle complex material and process system challenges with key stakeholders, including design, manufacturing, sourcing, quality, and business leaders.
- Support and implement technical roadmaps or testing plans that enhance understanding of innovative casting processes, precision ceramics, additive methods, and design.
- Participate in problem-solving initiatives for intricate and multifaceted manufacturing processes.
- Lead projects utilizing efficient operational and product management, manufacturing, or engineering techniques.
- Follow structured problem-solving methodologies, including the FLIGHT DECK operating system, while fostering a culture of LEAN and leveraging data for informed decision-making.
- Oversee material and process development from conception to production, focusing on TRL/MRL maturation of casting methods with an emphasis on quality.
- Contribute to producibility evaluations, including reviews and the establishment of best practices.
- Maintain documentation of lessons learned and new standards within established archival systems, communicating developments and solutions to the broader team, including leadership.
- Provide technical leadership in advancing innovative turbine airfoil designs, materials, and additive process paradigms.
- Engage in program reviews and prepare invention disclosures as necessary.

Required Qualifications
- Bachelor's Degree in Engineering from an accredited institution.
- Relevant experience in materials engineering, process design, and/or industry.
- A minimum of 3 years of experience in materials engineering, application, or manufacturing process development.
- Experience with ceramic core and casting development for turbomachinery components.
- Willingness to work on-site more than 75% of the time.
- US citizenship or green card holder required for compliance purposes.

Desired Characteristics
- Advanced degree (Masters or PhD) in Engineering.
- Strong verbal and written communication skills, with the ability to document, plan, market, and execute programs effectively.
- Excellent interpersonal skills and indirect team leadership capabilities.
- Proven ability to develop processes and procedures from concept to production release.
- Comfortable working in hands-on lab and pilot line environments.
- Demonstrated experience with Geometric Dimensioning and Tolerancing (GD&T).
- Ability to interpret technical drawings.
- At least 5 years of relevant design and/or manufacturing experience.
- Familiarity with the development of investment casting processes.
- Proven ability to work collaboratively and communicate effectively across the organization.
- Commitment to fostering a culture of respect for all individuals in all roles.
- Demonstrated problem-solving and program/project leadership skills.

Additional Information
ASM International offers a dynamic work environment, opportunities for professional growth, challenging career paths, and competitive compensation. ASM International is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status, or other characteristics protected by law.

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