About this job

Sapienza Consulting is recruiting a Materials & Process Evaluation Engineer to support ESA on site at ECSAT in the U.K.

Responsibilities

• In collaboration and support of the Metallic and Non-Metallic Materials and Processes Engineer, assess customers’ needs in relation to laboratory/analysis activities;
• Propose/realize test methods/setups to satisfy the customer needs;
• Design and perform non-standard tests to meet special space Projects requirements as well as develop in-situ analysis techniques;
• Perform all measurements and analyses on metallic as well as non-metallic materials (including all cleanliness and contamination control related activities as well as PCBs and electronic assembly) on a variety of destructive and non-destructive test equipment/tools. This includes also the issuing of dedicated testing procedures and documentation development as well as inclusion of test requests and test results in the relevant Quality Management Systems and databases;
• To set up and operate equipment/analysis tools devoted to the assessment of space environmental effects. This includes assessment by simulating the space environment (vacuum, radiation, ATOX, contamination, thermal ….) as well as pre/post characterisation by analytical techniques (thermal analysis, chemical analysis, physical and microscopic analysis, surface analysis, spectroscopic analysis, NDI techniques etc.)
• Use a variety of laboratory tools, including acoustic microscopy, optical microscopy, scanning microscopy, confocal microscopy, XRD, X-Ray imaging, NDI etc., XPS, surface tension, Auger Microscopy, Raman Spectroscopy, Atomic Force Microscopy, IST Testing;
• Perform mechanical and thermo-mechanical testing (including static, fatigue, fatigue crack propagation, Nano indentation, Nano scratch, low speed impact, hardness testing), also using contact and contact less in-situ strain measurement systems (strain gauges/ARAMIS);
• Perform all corrosion characterisation testing, including but not limited to stress corrosion, galvanic, red-plague, general corrosion, humidity/salt fog testing, etc.;
• Perform all thermal analysis on materials (including thermo-gravimetric, differential scanning calorimetry, thermo-mechanical as well as dynamic mechanical analysis, dielectric analysis, CTE determination, thermal diffusivity/conductivity analysis as well as coupled and advanced thermal modelling techniques for physico-chemical analysis.
• Support R&D activities with focus on metallic and non-metallic materials advanced evaluation/characterisation/verification methods covering the needs of future space missions;
• Support the laboratory equipment procurement definition and implementation;
• Perform all verification activities on Printed Circuit Boards and electronics assemblies;
• Record sample properties or condition during and after test, accurately and legibly;
• Review and issue relevant test reports for all performed test activities;
• Check on test equipment performance and reporting any anomalies or faults;
• Improve test procedures and ensuring that these are executed correctly;
• Maintain of the relevant test equipment, ensuring that the equipment under his/her responsibility is kept in an operational state

The laboratory tasks shall especially cover:

• End to end process evaluation for additive manufacturing, including raw material specification and product performance (mechanical testing, NDI, etc.).
• Destructive and non-destructive PCB testing.

Additional tasks shall cover:

• Provide materials and processes support for projects where product assurance and safety managers are located at ECSAT, including participation to projects meeting, reviews and audits;
• Support Materials and Processes reviews, Materials and Processes Control Boards (MPCB’s) and participate as Engineering and/or PA Board Member in ESA Programme reviews milestones (including PRRs, SRRs, PDRs, CDRs, QARs, FRRs, etc.);
• Review Declared Materials, Parts and Processes Lists (DMLs, DPLs, and DMPLs) as well as RFAs, RFDs/RFWs, ECPs, etc.;
• Support major Non-Conformances Review Board activities, perform failure analysis and failure investigation using a variety of laboratory tools;
• Support the definition and implementation of the Research and Technology activities in the domain of advanced manufacturing;
• Support the evaluation of proposals for technology R&D activities on their technical merit, consistency and priorities and recommendation for ESA endorsement;
• Support the coordination of technology R&D activities, monitoring of the procurement implementation, evaluation and reporting of the achieved results and lessons learnt to the relevant ESA Directorates and key Partners;

The technical competence shall especially cover:

• Processing (e.g. joining, surface treatments), testing, and performance evaluation of metallic materials (e.g. Al-alloys, Ti-alloys, steel).
• Additive manufacturing processes and associated test and qualification approaches.

Profile

• Master’s Degree in Engineering and Science, Materials Physics/Metallurgy and/or Non-Metallic Materials or equivalent
• At least 4 years of relevant work experience
• Several years’ industrial experience preferably covering aerospace hardware and R&D
• Strong materials laboratory hands-on experience related to metallic as well as non-metallic materials, manufacturing and applied processes characterisation/verification and failure investigation; a strong background on space simulation facilities is an asset.
• Knowledge of ISO 17025 related testing activities and ability to carry out testing and analysis in an ISO 17025 or other Quality Management System applicable standards.

This includes procedure and documentation development;

• Familiarity with data acquisition systems and software (e. g. LABVIEW);
• Ability to issue clear and concise materials testing reports;
• Familiarity with ESA Materials and processes related requirements;
• Understanding of space missions related requirements and capability to propose verification methods including testing, analysis, inspections;
• Good interpersonal and communication skills. Ability to work effectively, autonomously and cooperatively in a diverse and international team environment, defining and implementing solutions in line with team and individual objectives, as well as project deadlines.
• Good knowledge about general materials test methodologies and especially experience in mechanical testing.
• Experience in defining and executing test plans for materials qualification and process validation.
• Capability to take decisions for selection of materials and processes for space applications.
• Fluent in English; knowledge of another ESA member-state language is an asset