Senior FEA Engineer (Huntersville)

Senior Analysts serve as technical leads on complex life assessment, failure investigation, and design projects. Senior staff members are responsible for ensuring technical excellence, strengthening client relationships, and mentoring technical teams. Work includes leadership on high-complexity projects supporting the power generation and energy industries.

Key Responsibilities:

• Lead and manage complex engineering projects involving thermal heat transfer, creep and fatigue life assessment, fracture mechanics, and structural stress analysis using both classical and finite element methods
• Perform and review advanced FEA simulations using Abaqus or ANSYS, including nonlinear creep and time-dependent analyses
• Execute and oversee life assessment methodologies for creep, fatigue, and crack growth evaluations
• Provide technically defensible recommendations supporting continued operation, repair strategies, or remediation plans
• Participate in business development efforts, including cultivating client relationships, preparing and presenting proposals, developing new service offerings, and representing SI at industry events
• Mentor and train junior and mid-level engineers; lead technical peer reviews and contribute to SI engineering guidelines and procedures

Required Skills/Qualifications:

• B.S., M.S., or Ph.D. in Mechanical Engineering, Civil Engineering, or a closely related discipline
• M.S. or Ph.D.: 10+ years of relevant engineering experience
• 12+ years of relevant industry experience
• Knowledge of power generation and energy industry systems, particularly conventional boiler and combined cycle power plants
• Demonstrated experience with materials degradation mechanisms including creep and fatigue, high-temperature material behavior, and welding metallurgy
• Demonstrated experience performing fitness-for-service (FFS) assessments
• Advanced proficiency with Abaqus or ANSYS, SolidWorks modeling, and applied fracture mechanics principles
• Strong written and verbal communication skills with the ability to manage client engagements and lead complex technical teams

Preferred Qualifications:

• ASME Code Committee membership or active engagement
• Knowledge of ASME Boiler & Pressure Vessel Code requirements
• Professional Engineer (P.E.) licensure or progress toward licensure
• Familiarity with EPRI materials and analytical programs

Expected Contributions and Outcomes:

• Deliver high-quality, technically defensible reports that withstand peer and client review
• Expand SI’s market presence through strong client relationships and technical leadership
• Mentor and develop engineers to elevate overall team capability and technical excellence

Pay Range:

The expected salary range for this role is $171,000 – $227,800 in San Jose, CA; $144,400 – $195,400 in Denver, CO; 123,900 - 168,900 in Akron, OH; and $135,000 – $187,600 in Charlotte, NC. Exact pay will be commensurate with location, experience, and qualifications.

Export Control Notice:

Certain positions at SIA may require access to information and technology which is subject to Export Administration Regulations 15 CFR 730-774, including those of the US Department of Energy (DOE) in 10 CFR 810 and Nuclear Regulatory Commission (NRC) 10 CFR Part 110. Hiring decisions for such positions must comply with these regulations and may result in SIA limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List:

About Us:

At Structural Integrity Associates, Inc. (SIA), employees are proud to be part of a company where contributions are valued. Join a team of internationally recognized experts in a culture based on knowledge, excellence, and respect for one another. Our employees are members of a distinct community of internationally respected professionals committed to quality, engineering innovation and a shared goal of building a safer world.

Why Work at SIA?

SIA offers a competitive salary and performance-based bonus program. Our retirement benefits include a Traditional 401k, Roth 401k, and an employer match. To help employees maintain a work-life balance, SIA also offers various paid time off including vacation, floating holidays, sick time, and parental leave.

Our employees also enjoy a comprehensive benefits program that includes the following:

• Medical, dental, and vision insurance
• Life Insurance and AD&D
• Short-term and long-term disability
• Health Savings Account with employer contribution
• Flexible Spending Account for health care and dependent care
• ID theft protection and credit monitoring

Structural Integrity Associates, Inc. is an equal opportunity employer.

SIA does not welcome third-party recruiters, employment agencies, headhunters, etc. Please do not reach out to SIA employees requesting a call, sit down, meeting, or email response.

Candidate information may be verified during the hiring process. Inaccurate, deceptive, or mass-generated applications may be disqualified from consideration.