Senior Process Engineer- Nickel Plating​/Electroplating

SQA Services is seeking an experienced Aerospace Nickel Plating / Special Process Subject Matter Expert (SME) to support technical assessments, process remediation, supplier recovery activities, and process capability evaluations within aerospace manufacturing supply chains. The SME will provide hands‑on technical expertise in electroplating processes, special process controls, plating defect analysis, fixturing/racking optimization, and process validation at supplier manufacturing locations. The role will support aerospace customers experiencing plating‑related quality, dimensional, cosmetic, and process‑capability issues that impact production and delivery performance.

This position requires a deep technical understanding of aerospace plating processes and the ability to collaborate with suppliers, customers, manufacturing engineering teams, and quality organizations to identify root causes and implement sustainable corrective actions.

• 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

• 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

• 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

• 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

• 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

• 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

• 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

• 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

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

• 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…