Structural/Thermal Analyst – Turbine Blade and Casing Design

The Senior Structural/Thermal Analyst is a technical leader responsible for the analysis, evaluation, and lifecycle performance optimization of turbine blades, vanes, and casings under complex thermal and mechanical loading. This role involves advanced modeling and simulation of high-speed rotating components, supporting both new product development and fielded systems in demanding gas and steam turbine environments.

Key Responsibilities:

• • Lead finite element analysis (FEA) and thermal simulation of turbine components under high-temperature, pressure, and centrifugal loads.

  • Drive the evaluation of thermo-mechanical fatigue (TMF), low-cycle fatigue (LCF), creep, and vibration-related failures for blades, vanes, and casings.

  • Perform multi-physics simulations, integrating thermal, structural, and flow data for accurate design prediction and optimization.

  • Supervise or mentor junior and mid-level analysts; review models, analysis methods, and reporting for quality and accuracy.

  • Collaborate with design, aerodynamics, manufacturing, and materials teams to influence component geometry, coatings, and cooling strategies.

  • Define and validate thermal boundary conditions, including hot gas path distributions, film cooling, and heat soak behavior.

  • Lead design validation activities, including correlation of analysis with strain gauge and thermal test data.

  • Guide failure investigations and provide actionable insights for mitigation of cracking, deformation, and thermal distortion.

  • Support the development of automated analysis workflows, reusable modeling templates, and best practice guidelines.

  • Ensure compliance with industry codes and standards (ASME, API, ISO, OEM-specific standards).

Key Focus Areas:

• • High-Fidelity Structural & Thermal Analysis – Static and dynamic FEA, transient thermal loading, blade tip dynamics

  • Advanced Fatigue and Creep Life Prediction – TMF, LCF, creep-fatigue interaction, crack initiation and propagation

  • Blade-Casing Interaction & Contact Modeling – Tip rub analysis, differential growth, rotor/stator interaction

  • Hot-Section Component Behavior – Thermal gradients, oxidation, coating degradation, and material property shifts

  • Design Guidance & Risk Assessment – Critical location identification, margin calculation, design feedback loops

Qualifications and Skills:

• • Master’s or PhD in Mechanical, Aerospace, or Structural Engineering (or equivalent)

  • 8+ years of experience in structural and thermal analysis of turbomachinery components

  • Expertise with ANSYS, Abaqus, or similar FEA platforms; experience in scripting (Python, MATLAB) for analysis automation

  • Strong knowledge of material science, especially high-temperature alloys, TBCs, and superalloys used in turbine applications

  • Demonstrated experience in multi-disciplinary coordination and design influence across project lifecycles

  • Deep understanding of fatigue, fracture mechanics, creep, and thermal stress evaluation

  • Excellent technical writing and presentation skills for internal reviews and customer deliverables

Preferred Experience:

• • Prior work on aero-engine, marine propulsion turbines, or industrial gas/steam turbines

  • Experience with rotor dynamics, casing creep modeling, or combustor/turbine interface phenomena

  • Familiarity with DOE methods, probabilistic analysis, and digital twin applications for structural integrity

  • Hands-on exposure to test-data correlation, thermal instrumentation, or condition monitoring