Principal Thermal Engineer

Career Area: Engineering Job Description: Your Work Shapes the World at Caterpillar Inc. When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other. We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it. Solar Turbines’ GCE Mechanical and Electrical Analysis (MEA) Group is seeking a Principal Engineer specializing in thermal modeling and analysis to advance the thermal capability of Solar’s gas compressor product line. This role focuses on expanding compressor operating envelopes to cover high‑discharge‑temperature and low‑suction‑temperature applications through advanced modeling, simulation, and testing. Job Functions: Integrate seal‑supplier flow/heat‑loss data and Solar closed‑loop test data to build and refine flow and heat‑transfer co‑simulation models. Map thermal profiles across discharge‑side subassemblies including balance pistons, dry gas seals, separation seals, and surrounding cavities. Perform analytical calculations and, when required, CFD simulations to validate supplier flow/loss data. Develop guidelines for extrapolating predictions across seal sizes, types, and field operating conditions. Conduct Conjugate Heat Transfer simulations of rapid decompression events to characterize temperature evolution in compressor casings and internal components. Provide recommendations for material selection based on thermal response. Establish temperature limits, flow requirements, and pressure‑setting guidelines to support integration of new seal technologies and new suppliers to expand compressor operating envelope. Partner with software vendors to enhance co‑simulation tool capabilities and evaluate new tools for improved flexibility, accuracy, and efficiency. Work with Rotordynamics, Aerodynamics, and GCB CLTF testing teams to develop high‑discharge‑temperature test plans, implement loop modifications, and execute testing in the GCB closed‑loop facility. Minimum Requirements Master’s degree in mechanical or aerospace engineering. Six years of direct work experience on thermal modeling and analysis. Hands on experience with flow and heat transfer co-simulation and conjugate heat transfer simulation. Strong Foundation in Thermodynamics, Heat Transfer, and Computational Fluid Dynamics. Familiar with compressor thermal test instrumentation including RTD, thermal couples, flow transmitters, flow regulators and control valves. Proficiency with Ansys Mechanical, Flownex, Ansys Fluent, Ansys CFX and Matlab. Knowledge of various types of steel and alloys, for example, carbon and low alloy steels, stainless steel (austenitic and martensitic), and Nikel alloys, and their behavior across extreme temperatures. Preferred Requirements PhD in mechanical and aerospace engineering Four years of additional direct work experience on thermal modeling and analysis. Familiar Dry Gas Seal and Separation Seals technologies. Understanding of polymers used in seal technology. Experience reading and interpreting pipeline compression station P&IDs. Proficiency with Siemens Star-CCM+. Experience with Python Coding and Stress analysis using Ansys. Summary Pay Range: $120,600.00 - $180,900.00 Compensation and benefits offered may vary depending on multiple individualized factors, job level, market location, job-related knowledge, skills, individual performance and experience. Please note that salary is only one component of total compensation at Caterpillar. Benefits: Subject to plan eligibility, terms, and guidelines. This is a summary list of benefits. Medical, dental, and vision benefits* Paid time off plan (Vacation, Holidays, Volunteer, etc.)* 401(k) savings plans* Health Savings Account (HSA)* Flexible Spending Accounts (FSAs)* Health Lifestyle Programs* Employee Assistance Program* Voluntary Benefits and Employee Discounts* Career Development* Incentive bonus* Disability benefits Life Insurance Parental leave Adoption benefits Tuition Reimbursement * These benefits also apply to part-time employees This position requires working onsite five days a week. Visa Sponsorship is not available for this position. Posting Dates: Any offer of employment is conditioned upon the successful completion of a drug screen. Caterpillar is an Equal Opportunity Employer, Including Veterans and Individuals with Disabilities. Qualified applicants of any age are encouraged to apply. Not ready to apply? Join our Talent Community. Powering the future through innovative, sustainable energy solutions. Solar Turbines Incorporated, headquartered in San Diego, California, is a wholly owned subsidiary of Caterpillar Inc. Solar manufactures the world’s most widely used family of mid-sized industrial gas turbines, ranging from 1 to 39 megawatts. More than 16,000 Solar units are operating in more than 100 countries with more than 3 billion operating hours. Solar is a leading provider of energy solutions, featuring an extensive line of gas turbine-powered compressor sets, mechanical drive packages, and generator sets. Solar’s customers put the company’s products to work in many areas, including production, processing and pipeline transmission of natural gas and crude oil, and generation of electricity and thermal energy for processing applications, such as manufacturing chemicals, pharmaceuticals, and food products. Solar’s foundation is people and Solar’s culture is one where individual contributions are valued, diversity in the workplace is encouraged, and safety is emphasized in all aspects of the business. Solar Turbines is comprised of a dedicated and multi-talented workforce of more than 9,000 employees with decades of experience working as a global team.