About POWERTECH

POWERTECH is a center of excellence for propulsion technologies, specializing in the design, engineering, and manufacturing of combustion engines, expendable turbojet engines, and turbofan engines for a wide range of aerospace, defence, and autonomous applications, including fixed- and rotary-wing UAVs and other advanced platforms.

Role Overview

We are seeking a highly skilled Heat Transfer and Thermal Engineer to join our Aero Engine Technology Development Team. The position focuses on advanced gas turbine Thermal management and cooling technology (Combustion system and Hot gas path) for next-generation military gas turbine engines, with emphasis on high-efficiency combustion, liner and transition piece cooling, and additive manufacturing (AM)-enabled solutions.

The role spans the complete product lifecycle—from concept through TRL 7—and involves a combination of numerical analysis, design optimization, and experimental validation to deliver robust, mission-ready combustor hardware.

Key Responsibilities

1. Thermal & Cooling System Design

• Develop advanced cooling architectures (film, impingement, effusion, transpiration) for combustor liners, domes, and transition ducts suitable for military aero engine environments.
• Design AM-enabled cooling configurations that leverage lattice structures, conformal passages, and optimized cooling hole layouts to enhance thermal performance and manufacturability.
• Conduct steady-state and transient thermal analyses ensuring structural integrity and thermal margins under severe duty cycles.
• Integrate TBCs (Thermal Barrier Coatings) and advanced high-temperature materials into the design process for extended component life.

2. Combustion & Flow Modeling

• Perform 1D/2D thermal network modeling using in-house and commercial tools with heat transfer and pressure loss correlations.
• Execute 3D CFD and CHT simulations using STAR-CCM+ and ANSYS Fluent, including conjugate heat transfer and coolant flow predictions for complex AM geometries.
• Apply FEA-based thermal analysis using ANSYS/Simcenter 3D tools to evaluate material temperatures and thermal stress distributions.
• Conduct design trade studies between conventional and AM-based designs for cost, manufacturability, and performance optimization.

3. Additive Manufacturing Integration

• Collaborate with AM design and manufacturing teams to ensure design intent is maintained through print-ready geometry, build orientation, and post-processing.
• Apply Design for Additive Manufacturing (DfAM) principles to reduce weight, improve cooling effectiveness, and enable integrated functionalities.
• Validate AM cooling features through rig testing and non-destructive evaluation methods.
• Support material and process development for AM-produced combustor hardware, including heat treatment and coating compatibility.

4. Experimental Development & Validation

• Design and execute cooling and heat transfer rig tests for validation of analytical models and AM prototypes.
• Develop instrumentation plans (thermocouples, pressure transducers, IR thermography) and analyze test data to calibrate simulations.
• Correlate experimental results with computational predictions to refine design tools and methods.

5. Integration & Collaboration

• Interface with combustion/Hot gas path design, structural analysis, materials, and manufacturing teams to achieve performance and durability objectives.
• Participate in design and peer reviews with internal/external engineering partners.
• Support root cause analysis for thermal performance deviations and in-service findings.

6. Documentation & Reporting

• Prepare comprehensive technical reports, thermal analysis summaries, and validation documents for internal design reviews and program milestones.
• Present technical findings to leadership, certification authorities, and cross-functional review panels.

Required Qualifications

• Education:
• B.E./B.Tech. or M.E./M.Tech. in Mechanical, Aerospace, or Thermal Engineering (PhD preferred).
• Experience:
• Practical Experience in thermal system design, heat transfer analysis, or cooling optimization for aero gas turbine.
• Proven background in additive manufacturing design and analysis for thermal management or combustor components.
• Technical Skills:
• Expertise in STAR-CCM+, ANSYS Fluent, Simcenter 3D and ANSYS Thermal/Structural solvers.
• Proficiency in CAD tools (NX, SolidWorks) for complex model preparation and integration with simulation workflows.
• Strong understanding of fluid mechanics, thermodynamics, and heat transfer fundamentals with the ability to perform hand calculations and simplified modeling.
• Experience with AM design tools or DfAM principles (e.g., topology optimization, lattice design, build orientation).
• Familiarity with high-temperature alloys, TBC systems, and advanced cooling techniques.
• Behavioral Skills:
• Strong analytical thinking and technical problem-solving ability.
• Excellent communication and documentation skills.
• Ability to work effectively in cross-disciplinary and cross-cultural environments.
• Flexibility to travel for test campaigns and partner coordination.

Desirable Qualifications

• Experience in combustor hardware programs or Aero engine propulsion R&D.
• Knowledge of AM process simulation, distortion prediction, and post-processing methods.
• Familiarity with mission-based thermal loading and engine cycle coupling for aircraft propulsion.
• Understanding of emission reduction, combustion efficiency optimization, and pattern factor control.

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