Senior Aerospace Casting Engineer

Chromalloy is a global engineering & solutions company. We are a leading provider of aftermarket parts, repairs, and solutions that safely & reliably extend the life of aircraft engines and gas turbines. We develop, manufacture and repair critical turbine components for a range of engine platforms. Our solutions support the engines running the aerospace, energy and defense industries around the world.

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Why work at Chromalloy?

Chromalloy employees are proud, passionate problem-solvers who strive to live our values every day. A career with Chromalloy is an opportunity to learn from top industry experts, work with important technologies, and unlock a passion for innovation. Join our team of experts, innovators and problem-solvers delivering world-class solutions for our customers. As a global company, we are committed to creating an inclusive environment where all employees feel represented, heard, and able to bring their best selves to work every day. Be part of something bigger with Chromalloy

Our Total Rewards Program is designed to support you today and in the future.

• Comprehensive and flexible benefit options starting on day one, including medical, dental, vision, EAP, wellness incentives, and 401(k) with employer matching.
• Development & progression opportunities for every employee - regular performance conversations, training and development curriculum, and engineering fellowship programs.
• Paid time off, including vacation, sick time, paid holidays, and parental leave-all eligible on your first day of employment
• Competitive pay, including eligibility for quarterly and annual bonuses, depending on role and site.

Eligibility for individual benefit plans may vary based on employment status.

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

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.

Chromalloy participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S.

Any offer of employment will also be conditioned upon the successful completion of a background investigation and drug screen in accordance with company policy and applicable federal and state regulations.

Chromalloy is an equal opportunity employer - vets/disabled.

In the United States, if you need a reasonable accommodation for the online application process due to a disability, please contact: https://www.chromalloy.com/contact-us/

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