Casting Methoding Lead Engineer (Sand Castings)

Immensa; Dubai; On-site; AED 350,000 - 520,000; Full time

Job summary

Immensa in Dubai seeks a hands-on casting methoding expert to act as technical authority with our foundry supply base. You will run solidification simulations, assess supplier methods, and drive defect root-cause actions to ensure right-first-time casting of critical oil & gas spare parts.

The role requires 7+ years in steel and alloy sand castings, strong gating/riser design experience, and proficiency with MAGMASOFT or ProCAST. Travel to suppliers is expected.

Qualifications

• Design and review gating, risering, chilling and core layouts for steel and alloy sand castings.
• Run solidification simulations using MAGMASOFT or ProCAST and review suppliers' simulations and method cards.
• Lead defect root-cause investigations (shrinkage, porosity, inclusions, hot tears, misruns) back to the method, sand system or melt practice.
• Audit and qualify foundries, turn method reviews into a clear risk register, and liaise with suppliers' engineers and metallurgists.
• Review casting drawings (machining allowances, datums, tolerances) and disposition non-conformances.

Responsibilities

• Design and review gating, risering, chilling and core layouts for steel and alloy sand castings.
• Run solidification simulations (MAGMASOFT, ProCAST or equivalent) and critically review suppliers' simulations and method cards.
• Lead defect root-cause investigations and drive corrective actions with the foundry.

Skills

Casting method design

Root-cause analysis

Audit of foundries

Gating & risering design

Drawings review

Education

Bachelor's degree in Mechanical/Metallurgical Engineering

Tools

MAGMASOFT

ProCAST

Job description

About Immensa

Immensa is transforming how the world's largest energy companies address critical spare-part challenges. Our solutions help asset-intensive organizations decrease over-stocking, reduce downtime, manage obsolescence, and strengthen supply-chain resilience through advanced digital inventory and distributed manufacturing technologies. We partner with some of the world's largest Oil & Gas and industrial companies, supporting mission-critical operations where reliability, quality, and trust are essential.

The Role

We're looking for a hands-on casting methoding expert who can look at a pump, valve or impeller casting and design (or challenge) the method that makes it right first time. You'll be Immensa's technical authority with our foundry supply base. You'll run your own solidification simulations, take apart a supplier's method, trace defects to their root cause, and qualify the foundries that make critical Oil & Gas spare parts.

What You'll Do

• Design and review gating, risering, chilling and core layouts for steel and alloy sand castings (green sand / no-bake)


• Run solidification simulations (MAGMASOFT, ProCAST or equivalent) and critically review suppliers' simulations and method cards


• Lead defect root-cause investigations (shrinkage, porosity, inclusions, hot tears, misruns) back to the method, sand system or melt practice, and drive corrective action with the foundry


• Apply O&G casting standards and acceptance criteria: ASTM A703, A995, A216/A351, API 6A/6D, NORSOK M-650, RT/UT/MT/PT acceptance and weld-repair limits


• Audit and qualify foundries, turn method reviews into a clear risk register, and hold a technical position with suppliers' engineers and metallurgists


• Review casting drawings (machining allowances, datums, critical tolerances) and inspection data, and disposition non-conformances


• Support costing, lead times and on-time-in-full delivery for casting orders

What You'll Bring

• Bachelor's degree in Mechanical, Manufacturing, Production, Foundry or Metallurgical Engineering


• 7+ years designing methods for steel and alloy sand castings, in a foundry or for a foundry supply base


• Can run simulations yourself in MAGMASOFT, ProCAST or an equivalent tool


• A track record of defect root-cause work with measurable results (rejection, yield, weld-repair reduction)


• Working knowledge of O&G casting standards and NDT acceptance criteria


• Foundry audit and qualification experience


• Comfortable working across locations and time zones, with travel to suppliers

Nice to Have

• Pump, valve or impeller castings (WCB, CF8M, CA6NM, duplex)


• Experience in NORSOK M-650 qualified foundries


• Reverse engineering / spare-parts projects