Principal Casting Engineer – Aerospace

About the role

We are a leading aerospace and propulsion technology company seeking a Principal Engineer, Castings to act as the senior technical authority for casting equipment, tooling, processes, and metallurgy used in aero‑engine component production. The role combines hands‑on technical leadership with mentorship of engineering teams to drive excellence in investment casting technologies.

Key responsibilities

• Provide expert guidance on all technical decisions related to casting equipment, tooling, processes, and metallurgy for aero‑engine components.
• Lead investment casting operations for turbine airfoils and large structural castings, including equipment selection (vacuum induction melting furnaces, DS/SX furnaces, shell rooms, wax injection, NDT, HIP).
• Define tooling strategies such as wax dies, ceramic core tooling, shell systems, grain selectors, and starter blocks.
• Direct alloy selection, gating and feeding design, solidification modelling, and defect resolution (porosity, freckles, recrystallization, grain defects).
• Develop process specifications, qualification plans, and technical training curricula for the local team.
• Mentor junior engineers and serve as the in‑house expert on casting metallurgy and processes.

Required profile

• 15+ years of hands‑on experience in investment casting of aero‑engine components.
• Deep expertise in airfoil casting (equiaxed, DS, and/or SX) and large structural castings.
• Strong knowledge of nickel‑based superalloys (CMSX‑4, René N5, MAR‑M247, IN738) and associated heat‑treatment.
• Experience with shell systems, ceramic cores, and grain‑control techniques.
• Familiarity with simulation tools such as ProCAST or MAGMASOFT.
• Engineering degree in Materials Science, Metallurgy, or related field; PhD or equivalent technical depth strongly preferred.

Required skills

• Investment casting
• Vacuum induction melting
• DS and SX furnace operation
• Shell room and wax injection processes
• Nondestructive testing (NDT)
• Hot Isostatic Pressing (HIP)
• Wax die and ceramic core tooling
• Shell systems and grain control
• Alloy selection and gating design
• Solidification modelling
• Defect analysis (porosity, freckles, recrystallization)
• Nickel‑based superalloys (CMSX‑4, René N5, MAR‑M247, IN738)
• ProCAST, MAGMASOFT simulation software

What we offer

• Relocation support to Abu Dhabi for exceptional international candidates.
• Opportunity to lead cutting‑edge aero‑engine casting projects.
• Collaborative environment with world‑class engineering talent.