Senior Mechanical Thermal-Fluids Engineer

Salary range: $ - $. This is a general guideline. Pay will be based on scope, responsibilities, qualifications, business considerations, internal equity, and external market pay.

Fermilab seeks a Senior Mechanical Thermal-Fluids Engineer to lead the Thermal-Fluids Engineering Group, collaborating across the lab to design, fabricate, test, install, and operate accelerator components and systems. The role involves using tools such as ANSYS, NASTRAN, Siemens NX, and additive manufacturing to model, simulate, and prototype designs.

• Serve as the Thermal-Fluids Engineering Group leader.
• Act as Level 4 Technical Manager for the LBNF RAW Water Systems.
• Apply fundamental mechanical engineering concepts throughout project stages: design, review, procurement, fabrication, installation, test, and operation.
• Design, analyze, specify, and construct fluid‑cooling piping systems for the accelerator complex, controlling the temperature of beamline components.
• Lead mechanical‑system design, thermal‑fluid system design, piping fluid‑flow analysis, and heat‑transfer analysis.
• Support operations by troubleshooting system issues and designing upgrades to improve reliability.
• Participate in the design of compressible and in compressible thermal‑fluid systems for accelerator use.
• Fabricate systems using welding, brazing, bonding, and soldering techniques with materials such as aluminum, stainless steel, copper, brass, PVC, CPVC, and PVDF.
• Direct drafters, designers, technicians, and skilled trades on projects.
• Communicate with vendors, contractors, and fabricators via written specifications and engineering drawings.
• Oversee co‑op engineering students and interns on their projects.
• Perform duties in accordance with all environmental, health and safety regulations.

• Bachelor’s in an applicable engineering discipline from an ABET‑accredited institution with 8+ years of engineering experience, or Master’s with 6+ years of engineering experience.

• Clear written and verbal communication with customers, stakeholders, and team members.
• Effective work under shifting priorities and schedule requirements.
• Fluid mechanics, thermodynamics, heat transfer, piping network calculations, and engineering mechanics calculations (statics, stress, strain, deflection).
• Machine‑shop practices and techniques for fabricating complex hardware.
• Knowledge of welding and brazing practices (TIG, MIG, torch brazing) for piping fabrication.
• Strong computing skills: engineering calculations, 3‑D modeling, 2‑D drawings, FEA, data presentation, project cost estimates, schedules.
• Proficiency in AFT Fathom, AFT Arrow, ANSYS Workbench, ANSYS Fluent, or ANSYS CFX.
• Ability to create and read mechanical drawings, including piping and instrumentation diagrams (P&) and process piping flow schematics.
• Familiarity with CAD software for piping fluid‑flow network systems.
• Skills in AutoCAD Plant and geometric dimensioning & tolerancing.
• Problem‑solving and troubleshooting operational issues.
• Knowledge of materials, metallurgy, radiation damage and code standards such as ASME, AISC, ANSI/ASME pressure‑vessel and piping codes.
• Basic understanding of electrical engineering concepts.

• Human factors: heights, underground work, mental concentration, sitting, standing, tight schedules, visual demand.

• On‑site role at the Batavia office.

• Medical, dental, vision, and flexible spending accounts.
• Paid time off.
• Life insurance.
• Short‑term and long‑term disability insurance.
• Retirement benefits.
• Onsite day care.

Fermilab is an equal opportunity employer. We evaluate qualified applicants without regard to race, color, religion, sex, age, national origin, disability, veteran status, genetic information, and other legally protected categories.