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Senior Application Engineer, Structural Performance Technology

Company: Novelis Global R&T
Location: Novi
Posted on: January 12, 2022

Job Description:

Position Overview:Novelis is seeking an experienced automotive Body-in-White (BIW) / Closures Structural Engineer for a key role in the new automotive Customer Solution Center (CSC), in Novi, Michigan. The CSC is responsible to develop Closure and BIW designs in partnership with several automotive OEMs that balance cost, mass, and innovative products that demonstrate the value of Novelis products. The Senior Application Engineer will ensure these designs meet structural targets through analysis and simulation techniques.
The successful candidate will utilize CAE tools - both linear and non-linear and potentially optimization -to OEM desires and specifications, as well as for demonstration designs of new, innovative Novelis products. He/she will join a team of other automotive engineers proficient in automotive aluminum, structural design, joining methods, formability simulation, cost modeling, and CAD methods, with a mission to develop designs that balance different materials and joining methods. Over time, simulation methods for aluminum and hybrid structures will be developed and advised to OEM and other specialists. The Senior Application Engineer will be responsible to deeply understand these methods and how they relate to real-world performance, and develop test methods to prove this out (collaborating with design, R&D, and manufacturing personnel).
The Senior Engineer will be a key member of the CSC in Novi which collaborates with other CSCs around the globe. The CSCs will promote innovations in the area of aluminum applications to provide new technical solutions to customers and internal project teams. CSCs mission is to assure the adaption and validation of innovation and new products at customers. Many North American automotive OEMs are particularly interested in closures, and hence is a focus of this center. Closures may include side doors, liftgates, hoods, fenders, and EV battery enclosures. This role will report to the Senior Technical Manager of the CSC who will manage the priorities and strategic direction of the engineering team in Novi as described above.
This position will work closely with the Novelis OEM customer alloy development teams, R&D application engineers, and colleagues in Novelis CSCs in Europe and Asia. Integration into a multinational team and adaption of the Novelis cultural beliefs and living the culture is key for the success of the individual and the team!Responsibilities & Qualifications:Responsibilities

  • Understand structural performance of aluminum and hybrid closure and body-in-white structures, and simulation methods to evaluate these (e.g. strength, stiffness, durability, crashworthiness)
  • Develop and iterate models to ensure OEM and Novelis designs meet structural targets, while optimizing for mass, cost, and performance
  • Understand sophisticated modeling techniques - such as fracture modeling - to help develop methods that simulate new Novelis alloys with special characteristics in real-world situations
  • Collaborate meaningfully with team members specializing in design, joining performance, formability, and corrosion
  • Effectively engage with Automotive OEM design engineers to understand modeling techniques in order to provide feedback to Novelis
  • Maintain records and documents of material cards and completed models to develop a history of structural performance
  • Develop project proposals and meet project deliverables, commitments and timelines
  • Help review development strategy to ensure Novelis development is congruent with market needs through discussions with product management, alloy development teams, OEM customer teams and the R&D teamQualifications
    • Masters Degree in Mechanical, Metallurgical or Materials Engineering required
    • A successful candidate will have 5+ years of broad experience in performance simulation of Body-in-White and/or door-in-white assemblies for all common structural materials (various Al alloys, UHS / AHSS, CFK)
    • Experience with detailed crashworthiness, stiffness, strength (linear and non-linear cases) simulation
    • Experience in simulation of various joining technologies and impact on module performance
    • Experience using FEA software such as non-linear codes LS-DYNA, Autoform, PAMCRASH, or ABAQUS, and linear codes such as Optistruct, NASTRAN, or similar
    • Experience with topology and shape optimization codes is desired
    • Experience handling 3D CAD data generated by codes such as CATIA or NX
    • Strong interpersonal skills, both verbal and written, and capability to thrive in a multinational and multifunctional team environment
    • Results-oriented with motivation to develop new simulation techniques in conjunction with R&D resources and industry peers
    • Seek to develop innovative solutions that balance structural needs and cost requirements is essential
    • Ability to travel in the local or regional area up to 30% of the timeLocation Profile:Novelis' Novi office is located twenty-five miles northwest of the heart of the motor city. Its 50+ employees provide dedicated commercial technical and recycling teams for Novelis' growing automotive customer base. Novi is also the location of the company's newly announced Customer Solution Center which will accelerate innovation between Novelis and automakers for the next generation of vehicle design. As one of the fastest growing cities in Michigan Novi offers a host of destination shopping and specialty expos fine dining options and outdoor recreation activities. Our Novi team is a key sponsor to community events such as Habitat for Humanity and local schools with its FIRST Robotics team and STEM education programs.

Keywords: Novelis Global R&T, Novi , Senior Application Engineer, Structural Performance Technology, Engineering , Novi, Michigan

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