Compressor Aerothermal Senior Engineer

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 aerospace, defence, and autonomous applications. Our solutions support fixed- and rotary-wing UAVs as well as other advanced platforms, driving innovation and performance in aerospace propulsion.

Job Overview

The Senior Aerothermal Design Engineer – Axial Compressor Module is responsible for the aerodynamic and thermal design, performance optimization, and flowpath development of axial compressor stages in turbofan engines.

This role ensures that the compressor meets design objectives for pressure ratio, efficiency, operability, surge margin, and durability across the full engine operating envelope.

The engineer will collaborate with mechanical designers, CFD analysts, materials experts, and system engineers to deliver optimized, validated compressor flowpaths and stage designs.

Key Responsibilities

Aerodynamic Design & Stage Performance

• Design and optimize compressor airfoils, stators, and rotors for each stage to meet aerodynamic performance targets.

• Define and develop the flowpath geometry, including hub and shroud contours, blade stacking, and 3D shaping.

• Analyze and manage stage loading, incidence, diffusion factors, and losses.

• Ensure adequate stall margin and choke margin across flight conditions and transient operations (startup, acceleration, etc.).

Thermal and Cooling Design

• Evaluate and define cooling and thermal management strategies for rotor and stator components.

• Assess thermal gradients and expansion behavior to support mechanical and structural integration.

• Collaborate with secondary air systems (SAS) teams to route and balance flow for cooling, sealing, and pressurization.

Simulation and Performance Prediction

• Perform aerodynamic design and analysis using:

  • 1D/2D meanline and streamline curvature methods (e.g., Vista, AxStream)

  • 3D CFD simulations (ANSYS CFX, NUMECA, TRACE, Fluent, etc.)

• Generate performance maps for stage and module-level behavior.

• Support conjugate heat transfer (CHT) analysis with thermal and mechanical teams.

• Validate CFD models with test data and improve simulation fidelity.

Testing, Validation, and Data Correlation

• Define instrumentation strategies for rig and engine testing (pressure taps, thermocouples, unsteady probes).

• Analyze test data to assess real-world aerodynamic performance and validate design tools.

• Collaborate with test engineers and mechanical teams to resolve discrepancies between predicted and observed results.

• Contribute to performance tuning and operability enhancements based on test feedback.

Integration and Cross-Functional Support

• Work closely with mechanical engineers to ensure aerodynamic and mechanical requirements are balanced.

• Collaborate with structural and vibratory analysts to prevent flutter and ensure aeroelastic safety.

• Support systems and controls engineers on variable geometry (VSVs, VBVs) and operability logic.

• Participate in design reviews, FMEAs, root cause investigations, and engine cycle analysis.

Technology Development & Innovation

• Investigate and implement new aerodynamic technologies such as:

  • Advanced 3D blading

  • Boundary layer control (bleed, endwall contouring)

  • Active or passive stall margin improvement

• Contribute to research on next-generation engine cycles, including geared, hybrid-electric, or ultra-high bypass designs.

Qualifications & Experience

• Bachelor’s degree in Aerospace, Mechanical, or Aeronautical Engineering required; Master’s or PhD with emphasis on turbomachinery aerodynamics or heat transfer strongly preferred.

• 7–10+ years of experience in aerodynamic and thermal design of turbomachinery components, with direct experience in axial compressors.

• Experience in full product lifecycle: conceptual design, simulation, test, and certification support.

• Proficient in turbomachinery CFD tools (ANSYS CFX, Fluent, NUMECA, etc.) and 1D/2D preliminary design tools (Vista, AxStream, MISES, or equivalent).

• Familiarity with unsteady flow phenomena: rotating stall, surge, flutter.

• Knowledge of thermodynamics, fluid mechanics, and gas turbine performance principles.

• Understanding of FAA/EASA operability requirements and engine-level integration considerations.

Preferred:

• Experience with engine rig testing and performance map generation.

• Exposure to secondary air system design and inter-stage bleed management.

• Familiarity with variable geometry (VSV, VBV) control logic.

• Knowledge of conjugate heat transfer and blade heat soak modeling.

• Involvement in hybrid or geared turbofan technology programs.

Personal Attributes:

• Analytical, data-driven mindset with strong physics intuition.

• Collaborative and communicative in cross-functional teams.

• Curious and forward-thinking, with a focus on innovation and continuous improvement.

• Results-oriented with a drive to deliver high-performance, certifiable aerodynamic solutions.

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