Senior Finite Element Analysis Engineer (FEA)

We are seeking experienced Mechanical Integrity Engineers with strong expertise in Stress Analysis and Finite Element Analysis (FEA) to ensure the structural integrity and reliability of aerospace components. This role involves detailed mechanical analysis across a wide range of engine commodities and supports the full lifecycle of product development—from concept to in-service support and disposal.

Key Responsibilities:

• Perform stress analysis and FEA simulations to validate mechanical integrity of components such as fans, compressors, casings, combustors, turbines, and structures.
• Apply FEA tools (e.g., Abaqus, Ansys, LS-Dyna) to predict mechanical behavior under various loading conditions including fatigue (low & high cycle), creep, vibration, thermal loads, and extreme operating scenarios (blade-out, over-speed, burst duct).
• Conduct mechanical integrity assessments to ensure product robustness and compliance with design requirements.
• Support in-service engine safety through stress analysis and mechanical evaluations.
• Lead Design of Experiments (DoE) and mechanical testing to validate stress predictions and improve design reliability.
• Collaborate with multi-disciplinary teams to ensure designs meet performance, manufacturability, cost, and weight targets.
• Define and execute analysis plans aligned with project milestones, cost, and quality goals.
• Recommend design optimizations using Robust Engineering principles and stress analysis insights.
• Drive continuous improvement in FEA methods, stress analysis processes, and mechanical integrity tools.
• Act as a subject matter expert in stress analysis and FEA, sharing knowledge across engineering functions.

Technical Skills Required:

• Strong experience in Finite Element Analysis (FEA) using tools such as Abaqus, Ansys, LS-Dyna.
• Proficiency in stress analysis, mechanical behavior prediction, and failure mechanism evaluation.
• Familiarity with meshing tools (e.g., Hypermesh, Unigraphics) and data management systems (e.g., Teamcenter).
• Understanding of material science, crack propagation, contact mechanics, and thermo-mechanical fatigue.
• Ability to communicate complex FEA and stress analysis results to internal and external stakeholders.
• Knowledge of aerospace product integrity, liability, and certification frameworks.

Qualifications:

• Degree in Mechanical, Aerospace, or Structural Engineering (BE/BTech/MSc/MEng).
• 1 to 10 years of hands-on experience in FEA, stress analysis, and mechanical integrity in aerospace or related industries.