Life-Cycle Integrity Engineer – FEA & Fracture Mechanics

Structural Integrity Associates; Huntersville (NC); On-site; USD 98,900 - 135,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

Life Insurance and AD&D

Paid time off including vacation and parental leave

Retirement benefits with employer match

Job summary

Structural Integrity Associates is seeking a Mid-Level Analytical Engineer based in Huntersville, NC. The role includes performing advanced stress analysis, creep and fatigue evaluations for power generation equipment while supporting life assessments and reliability evaluations. Ideal candidates will have a relevant engineering degree with extensive experience and the ability to mentor junior engineers.

Responsibilities also include leading technical discussions, conducting analyses, and developing comprehensive reports for both internal use and client interactions.

Qualifications

• 6+ years of relevant engineering experience with M.S. or Ph.D.
• 8+ years of relevant industry experience with B.S.
• Knowledge of materials degradation mechanisms including creep and fatigue.

Responsibilities

• Lead finite element and fracture mechanics analyses.
• Perform life assessment calculations related to creep and fatigue.
• Prepare and deliver technical reports and presentations.

Skills

Knowledge of power generation systems

Proficiency in applied fracture mechanics principles

Strong written and verbal communication skills

Experience with creep and fatigue evaluations

Education

B.S., M.S., or Ph.D. in Mechanical or Civil Engineering

Tools

Abaqus or ANSYS

SolidWorks or comparable CAD software

Job description

The Mid-Level Analytical Engineer independently performs stress analysis, creep and fatigue evaluations, and fracture mechanics assessments for heavy equipment within the power generation and energy industries, particularly supporting combined cycle and conventional boiler power plants. This role combines advanced technical execution with client interaction and mentorship of junior staff. The position primarily supports life assessment, reliability evaluation, and failure investigation projects for operating industrial assets.

Responsibilities

• Lead finite element and fracture mechanics analyses addressing thermo-mechanical behavior, creep deformation, and fatigue life
• Perform life assessment calculations related to creep, fatigue, and crack growth mechanisms
• Interpret material behavior and apply established industry methodologies and best practices
• Prepare and deliver technical reports, client presentations, and calculation packages; respond to client technical inquiries and provide engineering recommendations
• Participate in proposal development, project scoping discussions, and technical business development activities
  
  

Required Qualifications

• B.S., M.S., or Ph.D. in Mechanical Engineering, Civil Engineering, or a closely related engineering discipline
• M.S. or Ph.D.: 6+ years of relevant engineering experience
• B.S.: 8+ years of relevant industry experience
• Knowledge of power generation and energy industry systems, particularly combined cycle and conventional boiler-fueled power plants
• Demonstrated experience with materials degradation mechanisms including creep, fatigue, and high-temperature material behavior
• Proficiency in applied fracture mechanics principles
• Working knowledge of fitness-for-service (FFS) assessment methodologies
• Proficiency with Abaqus or ANSYS finite element analysis software
• Proficiency with SolidWorks or comparable CAD software
• Strong written and verbal communication skills, including technical documentation and client interaction
• Willingness to travel approximately 10–15% annually to industrial environments to support site assessment teams and project execution
  
  

Enhanced Qualifications

• Programming or scripting experience in Python, R, or VBA to support automation of analysis workflows
• Professional Engineer (P.E.) licensure or progress toward licensure
• Knowledge of ASME Boiler & Pressure Vessel Code requirements
• Familiarity with EPRI materials and analytical programs
• Participation in ASME Code Committees or related industry technical groups
• Awareness of EPRI materials programs such as CSEF, MRP, and BWRVIP
  
  

Typical Projects and Deliverables

• Lead technical tasks as part of multidisciplinary project teams (typically 1–3 engineers), deliver complete report sections, and represent SI in client technical meetings
• Independently develop FEA models, perform sensitivity studies, and provide actionable engineering recommendations supporting inspection planning, repair strategies, and design modifications
  
  

The expected salary range for this role is $126,300 – $171,000 in San Jose, CA; $107,700 – $144,400 in Denver, CO; $98,900 – $135,000 in Charlotte, NC; and $91,400 – $123,900 in Akron, OH. Exact pay will be commensurate with location, experience, and qualifications.

Export Control Notice:

Certain positions at SIA may require access to information and technology which is subject to Export Administration Regulations 15 CFR 730-774, including those of the US Department of Energy (DOE) in 10 CFR 810 and Nuclear Regulatory Commission (NRC) 10 CFR Part 110. Hiring decisions for such positions must comply with these regulations and may result in SIA limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List: https://www.ecfr.gov/current/title-10/chapter-III/part-810/appendix-Appendix%20A%20to%20Part%20810.

About Us:

At Structural Integrity Associates, Inc. (SIA), employees are proud to be part of a company where contributions are valued. Join a team of internationally recognized experts in a culture based on knowledge, excellence, and respect for one another. Our employees are members of a distinct community of internationally respected professionals committed to quality, engineering innovation and a shared goal of building a safer world.

Why Work at SIA?

SIA offers a competitive salary and performance-based bonus program. Our retirement benefits include a Traditional 401k, Roth 401k, and an employer match. To help employees maintain a work-life balance, SIA also offers various paid time off including vacation, floating holidays, sick time, and parental leave.

Our employees also enjoy a comprehensive benefits program that includes the following:

• Medical, dental, and vision insurance
• Life Insurance and AD&D
• Short-term and long-term disability
• Health Savings Account with employer contribution
• Flexible Spending Account for health care and dependent care
• ID theft protection and credit monitoring
  
  

Structural Integrity Associates, Inc. is an equal opportunity employer.

www.structint.com

SIA does not welcome third-party recruiters, employment agencies, headhunters, etc. Please do not reach out to SIA employees requesting a call, sit down, meeting, or email response.

Candidate information may be verified during the hiring process. Inaccurate, deceptive, or mass-generated applications may be disqualified from consideration.

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