Fracture Control Engineer

Overview

Fracture Control Engineer - Thales Alenia Space

Thales Alenia Space is a joint venture between Thales (67%) and Leonardo (33%). We design and manufacture space systems for telecommunications, navigation, Earth Observation, environmental management, science and orbital infrastructures. Our teams work to connect, secure and defend space assets while exploring and navigating the space environment.

We are looking for a Fracture Control Engineer who will define project solutions for manned pressurized structures and unmanned aerospace missions, ensuring components withstand launch, mission loads, re-entry and impact loads.

For manned missions and reusable spacecraft, structural integrity and life verification are performed to reduce failure risk due to crack initiation and propagation under cyclic loads during mission life. The activity covers primary and secondary structures, pressure vessels, pressurized structures, composites and non-metallic materials, glass and ceramic.

Responsibilities

• Prepare the Fracture Control Plan at the beginning of the program.
• Identify Fracture Critical Items during all design phases.
• Define the verification approach (safe life, fail safe, low risk).
• Define loads exceedance for fatigue load spectrum preparation.
• Perform detailed fatigue and fracture mechanics analyses.
• Define material characterization tests (fracture toughness, crack growth, stress corrosion).
• Define defect acceptability for welds and composite materials.
• Support Fracture Control Board discussions or alternative approaches.
• Contribute to competency development in fatigue and fracture mechanics analysis, support structural tests, NDI solutions, and management of Waivers and NCRs.

Knowledge of ESA and NASA standards for human spaceflight is essential.

Key duties

• Design and analyze spacecraft structures for manned and unmanned modules and satellites.
• Finite Element Modelling (static and dynamic) using FEMAP, Patran, or HyperMesh for pre/post processing.
• Structural analysis (fail safe, low risk) based on FEM (Nastran, Ansys, Radioss).
• Detailed verification through structural analyses: fatigue and fracture mechanics, using hand calculations or NASGRO/ESACRACK.
• Prepare reports (Fracture Analysis and Test Reports, Fracture Control Plan, NDI Plan, Fracture Critical Item List).

Skills, Experience and Qualifications

• At least 5 years of experience in the requested discipline is preferred.
• Experience in Structural or Mechanical Engineering for structures and mechanical systems.
• Strong Windows Office proficiency.
• Knowledge of aerospace damage tolerance standards (NASA, ESA, and other agencies).
• Knowledge of Space Station System standards for human flight missions.
• Extensive knowledge of metallic and non-metallic materials technologies.
• Mechanical engineering knowledge and expertise; CAD/CAM basics.
• Ability to read manufacturing drawings.
• Experience with NASGRO/ESACRACK codes; Nastran/Patran; ANSYS; HyperWorks; Femap.
• Strong analytical, synthesis and problem-solving skills.
• Excellent English (spoken and written); Italian language is a plus.
• Willingness to travel and work in shifts if required; ability to collaborate across teams and with Space Agencies and Subcontractors.

Education

• Master's Degree in Aerospace, Aeronautical or Mechanical Engineering.
• Master or specialized courses in Mechanical Design.

At Thales Alenia Space we provide careers and mobility across 10 countries with 17 sites in Europe and a US plant. Our mobility policy supports career development at home and abroad. Space for Life.