Interim Senior Process Engineer - Nickel Plating​/Electroplating

Senior Process Engineer
- Nickel Plating/ Electroplating

Location: Baltimore, MD

Employment Type: Contract:
Full-Time

Work Arrangement: On-site

Duration: Short-term (2-week) consulting position working full-time hours on the first shift

Compensation: $80 - $100 an hour

Technical Process Assessment

• Perform onsite assessments of aerospace electroplating operations including nickel plating and related special processes
• Evaluate plating process flow, controls, equipment, chemistry management, and operator practices
• Assess process stability, repeatability, and overall process maturity
• Identify process gaps, risk areas, and probable root cause contributors

Racking & Fixturing Evaluation

• Evaluate rack design suitability and current distribution effectiveness
• Assess electrical contact integrity and repeatability
• Analyze part orientation, shielding, thieving, and loading configurations
• Identify conditions contributing to plating thickness non-uniformity, edge buildup, burning, bubbling/blistering, gas entrapment, cosmetic defects, or inadequate coverage

Defect Investigation & Root Cause Analysis

• Support technical investigations involving plating defects and process instability
• Review interactions between machined part geometry, surface finish, process controls, fixturing, and plating outcomes
• Participate in root cause analysis and corrective action development
• Validate effectiveness of implemented corrective actions

Process Validation & Trial Support

• Witness plating trials and corrective action implementation activities
• Support evaluation of revised fixturing and process parameter adjustments
• Review thickness mapping and inspection results
• Assess process repeatability and capability indicators

Supplier Technical Support

• Interface directly with supplier engineering, quality, and operations teams
• Provide technical recommendations for process improvement and stabilization
• Support supplier recovery and process remediation activities
• Communicate technical findings clearly to customer and supplier leadership

Documentation & Reporting

• Generate detailed technical assessment reports
• Document process gaps, observations, risks, and recommendations
• Support development of remediation plans and process improvement roadmaps
• Provide objective technical recommendations regarding supplier viability and process capability

Candidates should possess strong working knowledge of:

Aerospace Electroplating Processes

• Nickel plating
• Electroless nickel processes
• Aerospace special process controls
• Surface preparation and activation methods
• Cleaning and pretreatment operations
• Plating chemistry fundamentals
• Current density effects
• Hydrogen-related plating risks
• Cosmetic and functional plating defect mechanisms

Racking & Current Distribution

• Rack design principles
• Shielding and thieving methods
• Electrical contact optimization
• Part orientation effects
• Current path distribution
• High/low current density effects
• Fixture repeatability and maintenance

Inspection & Verification

• Plating thickness measurement methods
• XRF systems
• Cross-sectional analysis
• Measurement system considerations
• Inspection methodology evaluation
• Interpretation of plating specifications and acceptance criteria

Aerospace Manufacturing Environment

• Aerospace quality systems
• Special process controls
• Root cause and corrective action methodologies
• Process capability concepts
• Engineering drawing interpretation
• GD&T interpretation
• Supplier quality expectations within aerospace manufacturing

• 10+ years of aerospace electroplating or special process experience
• Experience supporting aerospace OEMs or Tier 1 suppliers
• NADCAP special process experience strongly preferred
• Experience with nickel plating process troubleshooting and remediation
• Experience with complex machined aerospace hardware
• Experience supporting supplier recovery activities
• Strong technical writing and reporting capabilities
• Ability to work independently onsite at supplier facilities

Experience supporting one or more of the following industries is preferred:

• Aerospace
• Space launch systems
• Defense
• Precision machining
• Flight hardware manufacturing
• High-reliability manufacturing environments

• Strong technical troubleshooting capability
• Hands‑on process evaluation mindset
• Ability to communicate effectively with both executive leadership and shop floor personnel
• Objective and data‑driven decision making
• Collaborative but technically assertive approach
• Ability to rapidly assess manufacturing risk and process maturity

• Significant onsite supplier support activities may be required
• Travel to customer and supplier manufacturing locations required
• Short-duration intensive technical assessments and remediation activities typical

• Must be ITAR compliant and willing to undergo a background check