Principle Product Engineer - Casting

RTX (Raytheon); Asheville (NC); On-site; USD 150,000 - 190,000; Full time

Job summary

Pratt & Whitney is seeking a Senior Casting Engineer to strengthen our single-crystal airfoil casting capability in Asheville, NC. You will lead metallurgical process development for SX castings, ensuring quality and alignment with engine program requirements.

This role requires extensive experience in nickel-based superalloy metallurgy, demonstrated leadership, and collaboration with cross-functional teams to achieve defect-free SX structures and reliable manufacturing readiness.

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science, or related field with nickel-based superalloy focus.
• 10+ years in aerospace investment casting of SX/DS turbine airfoils; 7+ years if advanced degree.
• Mastery of superalloy solidification, defect prevention, thermal control strategies, and crystallographic orientation management.
• Experience qualifying new casting equipment and supporting manufacturing readiness activities.

Responsibilities

• Support metallurgical process development, qualification, and continuous improvement for SX airfoil casting processes.
• Develop and optimize SX solidification parameters including mold preheat, withdrawal profiles, thermal gradients, starter performance, and grain orientation control.
• Provide technical direction on melt practices, alloy cleanliness, pouring parameters, and mold/metal interface behavior to ensure defect-free SX structures.
• Support installation, testing, and acceptance of new casting equipment and enable full manufacturing readiness during process launch.
• Implement engineering changes, metallurgical controls, and process improvements to meet cost, yield, and on-time delivery goals.
• Evaluate metallographic results, perform root-cause investigations on casting defects, and define corrective actions.
• Support risk mitigation activities and ensure MRL alignment during program ramp-up.
• Mentor and develop early-career engineers in casting metallurgy, solidification science, and turbine airfoil manufacturing best practices.

Skills

Aerospace casting

SX/DS casting

Metallurgical engineering

Project leadership

Six Sigma Green Belt

Crystallographic orientation

Education

Bachelors in Metallurgy/Materials Science

Advanced degree in Metallurgy

Job description

Position Role Type: Onsite

U.S. Citizen, U.S. Person, or Immigration Status Requirements: U.S. citizenship is required, as only U.S. citizens are authorized to access information under this program/contract.

Security Clearance Type: None/Not Required

Security Clearance Status: Not Required

Location: US-NC-ASHEVILLE-330 ~ 330 Pratt Whitney Blvd ~ PRATT WHITNEY

This position will be based on-site in Asheville, NC.

About the Company

At RTX, the world's largest aerospace and defence company, 185,000 great minds are united by purpose and inspired to make a difference solving the world's most complex problems. With our three market leading businesses, world‑class operations and investments in research and development, we offer capabilities and opportunity no one else can. Together, we push the boundaries of known science and find new ways to connect and protect our world.

Pratt & Whitney

Pratt & Whitney is a world leader in the design, manufacture and service of aircraft engines and auxiliary power systems and has been revolutionizing modern flight for over 100 years. Join us and help shape the future of aerospace and defense.

Are you ready to go beyond?

Pratt & Whitney is transforming the future of flight by designing, building, and servicing propulsion systems unlike any the world has ever seen. Our new, world‑class 1,000,000‑square‑foot Asheville facility is home to an advanced turbine airfoil casting foundry supported by machining, coating, and finishing operations. As part of our continued growth, we are seeking an experienced Senior Casting Engineer to strengthen our single‑crystal (SX) airfoil casting capability and mentor the next generation of foundry engineers.

If you're ready to apply your casting expertise to a state‑of‑the‑art production environment, and help build a team capable of supporting a multi‑hundred‑million‑dollar investment in turbine airfoil manufacturing, we'd love to meet you.

What You Will Do

• Support metallurgical process development, qualification, and continuous improvement for single‑crystal turbine airfoil casting processes, ensuring compliance with quality and engine program requirements.
• Develop and optimize SX solidification parameters including mold preheat, withdrawal profiles, thermal gradients, starter/crystal selector performance, and grain orientation control.
• Provide technical direction on melt practices, alloy cleanliness, pouring parameters, and mold/metal interface behavior to ensure defect‑free SX structures.
• Support installation, testing, and acceptance of new casting equipment from vendors and enable full manufacturing readiness during process launch.
• Implement engineering changes, metallurgical controls, and process improvements to meet cost, yield, and on‑time delivery goals in a production foundry environment.
• Evaluate metallographic results, perform root‑cause investigations on casting defects (freckle, stray grain, porosity, carbide distribution, etc.), and define corrective actions.
• Support risk mitigation activities and ensure MRL alignment during program ramp‑up.
• Mentor and develop early‑career engineers in casting metallurgy, solidification science, and turbine airfoil manufacturing best practices.
• Collaborate cross‑functionally with shell, melt, automation, and machining groups to drive foundry excellence.

Qualifications You Must Have

• Bachelor's degree in Metallurgical Engineering, Materials Science, or related discipline with specialization in nickel‑based superalloy metallurgy. OR and advanced Degree with a focus in one of these areas.
• 10+ years of experience in aerospace investment casting of single‑crystal or directionally solidified turbine airfoils (SX/DS). If you have an advanced degree, 7+ years of related experience will be accepted.
• Demonstrated mastery of superalloy solidification, defect prevention, thermal control strategies, and crystallographic orientation management.
• Experience qualifying new casting equipment and supporting manufacturing readiness activities.
• Strong project engineering, communication, and technical leadership skills.
• Six Sigma green belt or equivalent.
• US Person / US Citizen status required due to government contracts.
• Proven ability to manage metallurgy‑focused technology development initiatives, lead teams, and control budgets.

Qualifications We Value

• Six Sigma black belt or equivalent.
• Master's degree in Metallurgy, Materials Science, or related engineering field.
• Experience with automation and high‑precision process control systems used in investment casting.
• Broad knowledge of the aerospace industry and experience in turbine engine parts manufacturing.