Senior Manufacturing Engineer – Primary Metal Processes
Join Frazer-Nash Consultancy as a Senior Manufacturing Engineer focused on heavy plant equipment (castings and forging). This role is central to translating route, metallurgy, and test evidence into engineering decisions that meet highly regulated standards.
Salary range: £65,000 to £80,000 per annum (depending on experience)
Location: All UK Offices
Working pattern: Flexible hybrid – time split between office and working from home
Closing date: 17th January (may close earlier if sufficient applications)
The Role
As a Senior Manufacturing Engineer – Primary Metal Processes (Casting and Forging), you will provide technical leadership across the supply chain for heavy plant equipment. You will work closely with design, integrity, quality and suppliers to ensure that primary processing routes deliver the required microstructure and mechanical performance, supported by appropriate codes, standards and testing evidence.
What You’ll Be Doing
* Provide engineering input on casting and forging routes for heavy plant components from specification through supplier delivery.
* Assess how primary processing choices (melt practice, solidification, reduction ratio, heat treatment) influence microstructure and mechanical properties of the end product.
* Apply practical metallurgy across ferrous and non-ferrous alloys, including steels and nickel‑based alloys.
* Support manufacture and assurance of highly regulated equipment (e.g., nuclear‑class components, pressure vessels, safety‑significant plant).
* Interpret and apply codes and standards, with particular focus on RCC‑M and ASME/ASTM (plus associated material specs and testing standards).
* Link degradation mechanisms (toughness loss, fatigue, creep, corrosion‑assisted mechanisms) to starting microstructures and processing history.
* Define, support and review materials testing programmes and evidence packs, including tensile, impact and toughness and related acceptance criteria/traceability.
* Prepare and review technical documentation: material and process specifications, supplier requirements, concession/deviation assessments and compliance/substantiation reports.
* Work with suppliers and stakeholders to resolve technical issues (non‑conformances, test anomalies, property shortfalls) with clear, auditable engineering reasoning.
* Capability development & mentoring: Help shape and continually improve defined development pathways—upskilling junior mechanical/materials engineers (through on‑the‑job learning and formal qualifications) in manufacturing, primary metal processes and welding technologies, while actively mentoring and coaching engineers as they develop.
Essential Requirements
* Strong experience in casting and/or forging of heavy plant equipment (or equivalent large‑scale, safety‑significant components).
* Solid understanding of metallurgy for steels and nickel‑based alloys, and how primary processing drives microstructure/property outcomes.
* Confidence working within highly regulated manufacturing environments (nuclear, pressure systems, defence, or similar).
* Working knowledge of RCC‑M and/or ASME/ASTM frameworks and how they translate into procurement specs, testing evidence and compliance.
* Familiarity with materials testing (tensile, impact, toughness) and the ability to interpret results in context (heat treatment, section size, sampling location, variability).
* Ability to write clear, defensible technical documentation suitable for audits and safety cases.
* Experience delivering outcomes in regulated manufacturing with demonstrated technical leadership and risk management.
Desirable Requirements
* Background in engineering consultancy (helpful, not required).
* Exposure to manufacturing/qualification of nuclear or defence components, high‑integrity welding interfaces, or formal qualification programmes.
Pre‑Employment Screening
Due to the nature of the work that Frazer‑Nash Consultancy undertakes, candidates will be required to undergo pre‑employment screening and must be able to satisfy clearance criteria for UK National Security Vetting.
Benefits
* Competitive salary with yearly reviews
* 25 days holiday + the opportunity to buy 5 days
* Company pension scheme
* Enhanced parental benefits
* Targeted professional development
* Life assurance
* Private healthcare membership
* Bonus scheme linked into company performance
* Paid membership fees to a professional institution
* Support in attaining professional membership
* Cycle to work scheme
* Season rail ticket loan
* Flexible working
Seniority Level
* Mid‑Senior level
Employment Type
* Full‑time
Job Function
* Engineering and Information Technology
* Business Consulting and Services
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