Senior Manufacturing Engineer – Primary Metal Processes
Frazer-Nash Consultancy is looking for a Senior Manufacturing Engineer to lead primary metal process engineering for heavy plant equipment. Salary: £65,000 to £80,000 per annum (depending on experience). Location: All UK Offices. Working Pattern: Flexible hybrid working (office & home). Closing date: 17th January (may close earlier if sufficient applications).
Role Overview
As a Senior Manufacturing Engineer – Primary Metal Processes (Casting and Forging), you will provide technical leadership across the supply chain for heavy plant equipment, working closely with design, integrity, quality and suppliers to ensure that primary processing routes deliver the required microstructure and mechanical performance, supported by codes, standards and testing evidence in highly regulated environments.
What You’ll Be Doing
* Provide engineering input on casting and/or forging routes for heavy plant components (from specification through supplier delivery).
* Assess how primary processing choices (e.g., 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 (e.g., 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 (e.g., non‑conformances, test anomalies, property shortfalls) with clear, auditable engineering reasoning.
* Capability development & mentoring: help shape and continually improve development pathways, upskilling junior engineers through on‑the‑job learning and formal qualifications, and actively mentoring and coaching engineers as they develop.
Essential Qualifications
* 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 Ni‑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 and leadership—not arbitrary years‑of‑experience thresholds—demonstrable technical leadership and risk management in regulated manufacturing.
Desirable Qualifications
* Background in engineering consultancy (helpful, not required).
* Exposure to manufacturing/qualification of nuclear or defence components, high‑integrity welding interfaces, or formal qualification programmes.
Due to the nature of the work, candidates will be required to undergo pre‑employment screening and must satisfy clearance criteria for UK National Security Vetting.
Benefits
* Competitive salary with yearly reviews
* 25 days holiday + the opportunity to buy 5 days
* Company that has its heart in the right place and a welcoming work culture
* Flexible working options
* Enhanced parental benefits
* Company pension scheme
* Targeted professional development
* Life assurance
* Private healthcare membership
* Bonus scheme linked to company performance
* Paid membership fees to a professional institution
* Support in attaining professional membership
* Cycle to work scheme
* Season rail ticket loan
* Optional benefits tailored to personal requirements
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