Torchora
Back to Home

Key Responsibilities and Required Skills for Jet Engine Tester

💰 $55,000 - $110,000

AerospaceEngineeringTestingPropulsion

🎯 Role Definition

The Jet Engine Tester is responsible for planning, executing, and documenting ground-based tests of turbofan, turbojet and turboprop engines in a controlled test cell environment. This role requires hands-on operation of engine test cells, instrumentation and data acquisition systems, troubleshooting of mechanical and control-system anomalies, and strict adherence to safety and regulatory standards (FAA/EASA). The Jet Engine Tester works closely with propulsion engineers, maintenance crews, and certification authorities to validate engine performance, reliability, and compliance during development, production acceptance, and overhaul verification tests.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Propulsion Technician / Engine Mechanic (A&P)
  • Test Cell Technician or Engine Test Assistant
  • Mechanical or Aerospace Engineering Technician

Advancement To:

  • Senior Jet Engine Tester / Lead Test Cell Operator
  • Propulsion/Test Engineer
  • Test Cell Manager / Test Operations Supervisor
  • Certification or Validation Engineer

Lateral Moves:

  • Flight Test Engineer
  • Field Service Engineer (engine OEM)
  • Quality Assurance / Reliability Engineer
  • Maintenance Program Manager

Core Responsibilities

Primary Functions

  • Develop, review and execute detailed engine test plans and run cards for developmental, qualification, production acceptance, and endurance tests, ensuring objectives, pass/fail criteria, and instrumentation requirements are clear and achievable.
  • Operate engine test cells during hot-fire, run-up and shutdown sequences, controlling fuel schedules, starting systems, and engine auxiliaries while monitoring safety interlocks and emergency shutdown procedures.
  • Install, calibrate and verify instrumentation and sensors (thermocouples, pressure transducers, strain gauges, torque meters, accelerometers) and ensure DAQ (data acquisition) systems are configured correctly for each test point and sampling rate.
  • Acquire high-fidelity engine performance and health data (EPR, EGT, N1/N2, fuel flow, torque, vibration spectra), validate data integrity during runs, and archive raw data in accordance with company and regulatory standards.
  • Conduct pre-test and post-test inspections, including borescope inspections, visual checks, and leak tests; document findings and escalate any airworthiness or safety concerns to engineering and maintenance leads.
  • Troubleshoot and isolate mechanical, electrical and control-system faults on engines and test cell systems using technical orders, wiring diagrams, control schematics, and diagnostic software.
  • Execute engine transient and steady-state performance tests, including acceleration/deceleration profiles, idle stability, surge/stall characterization, and map point captures to support engine modelling and certification.
  • Perform vibration and rotor dynamics tests (sweeps, bump tests, run-up vibration monitoring), capture frequency response, and collaborate with vibration analysts to interpret spectra and recommend corrective actions.
  • Implement safety-critical procedures including confined-space entry, hot-work permits, hazardous energy control (lockout/tagout), and work with safety officers to maintain a safe test cell environment.
  • Coordinate with propulsion engineers and OEM/customer representatives during witnessed tests, incorporate engineering test objectives, and provide on-the-spot data summaries and technical clarifications.
  • Prepare comprehensive test reports, including test objectives, setup photos, instrumentation lists, run logs, data trends, anomaly descriptions, and recommended corrective actions for engineering disposition.
  • Maintain and update test cell hardware and software inventories, perform preventative maintenance on test stands, fuel systems, ducts, and cooling systems, and schedule repairs with maintenance teams to minimize downtime.
  • Participate in root-cause analysis and failure investigation for in-test or post-test anomalies; collect and preserve evidence, assist in disassembly/inspection, and contribute to corrective action plans.
  • Support engine health monitoring and fleet trending activities by uploading test results to central databases, tagging test metadata, and ensuring traceability of engine serial numbers and configuration states.
  • Validate and qualify new or modified test procedures, instrumentation methods, and data reduction techniques; collaborate on developing improved instrumentation harnesses and sensor placements to increase test fidelity.
  • Ensure compliance with regulatory requirements (FAA, EASA, customer-specific specifications) and company quality systems (AS9100) during all phases of testing and documentation.
  • Operate and maintain control-room software including data acquisition platforms (e.g., LabVIEW, NI DAQ, Straton, DEWESoft), engine control interfaces (FADEC simulators), and test automation scripts, making minor script changes where authorized.
  • Lead or participate in test readiness reviews (TRR), hazard assessments, and mission briefings; ensure all stakeholders understand the test scope, constraints, and safety margins prior to execution.
  • Provide hands-on training and mentorship to junior technicians and rotating staff on test cell procedures, safety protocols, instrumentation techniques, and engine handling practices.
  • Manage fuel handling and conditioning procedures: fuel sampling, filtration checks, heat tracing, and monitoring fuel quality to prevent contamination-related anomalies during tests.
  • Execute environmental and endurance testing such as altitude simulation, icing risk mitigation, hot-section endurance, and thermal soak tests, documenting performance degradations and recovery behaviors.
  • Identify continuous improvement opportunities in test processes, test cell configuration, and data workflows; propose engineering changes or tooling enhancements to improve throughput and reduce test risk.
  • Liaise with procurement and spares teams to ensure critical test cell consumables and engine spare parts are stocked, rotated, and available for scheduled tests to avoid interruptions.
  • Maintain strict chain-of-custody for test samples, hardware removed during inspections, and evidence for non-conformance reports; ensure all materials are tagged, logged, and stored per procedures.

Secondary Functions

  • Support ad-hoc instrumentation calibration projects and coordinate with metrology labs for sensor recertification.
  • Contribute to test automation and scripting improvements to streamline repetitive run sequences and data extraction for engineers.
  • Assist in preparation of proposals, cost estimates and resource plans for engine test campaigns and special customer workscopes.
  • Participate in cross-functional continuous improvement events (Kaizen) focused on test cell throughput, safety, and data quality.
  • Help maintain the test cell facilities, including housekeeping, fire suppression checks, and return-to-service activities after major tests.
  • Provide technical support for field test campaigns, including mobilizing portable DAQ, instrumentation packs, and test stand adapters to customer sites.
  • Participate in internal audits and support corrective action implementation related to test processes, documentation and safety practices.

Required Skills & Competencies

Hard Skills (Technical)

  • Hands-on engine test cell operation and run-up experience with turbofan, turbojet or turboprop engines.
  • Test planning and execution: developing run cards, defining test points, and documenting test objectives and acceptance criteria.
  • Instrumentation and sensor installation: thermocouples, pressure transducers, torque cells, accelerometers, strain gauges.
  • Data acquisition system setup and troubleshooting (NI LabVIEW, NI DAQ hardware, DEWESoft, or equivalent).
  • Engine control interfaces and FADEC systems familiarity, including simulated control inputs and fault injection.
  • Vibration analysis and rotor dynamics test techniques (modal tests, spectrum analysis, order tracking).
  • Thermodynamics and propulsion fundamentals: understanding engine performance maps, thrust/torque curves, and gas-path measurement interpretation.
  • Borescope inspection techniques and fracture/erosion detection in hot-section components.
  • Root cause analysis methodologies (5 Whys, Fishbone/Ishikawa) and failure investigation experience.
  • Safety systems and regulatory compliance: FAA/EASA certification processes, AS9100 quality standards, and facility safety protocols.
  • Strong mechanical and electrical troubleshooting skills, ability to read schematics, P&IDs, wiring diagrams.
  • Data processing and analysis using MATLAB, Python (pandas/numpy), Excel, or specialized engine analysis tools.
  • Test automation and scripting for DAQ systems and control-room workflows.
  • Experience with test cell utilities: fuel systems, cooling systems, air handling, and exhaust configurations.
  • Documentation and technical report writing for engineering review and certification packages.

Soft Skills

  • Clear and concise technical communication for internal teams and external customers.
  • Strong attention to detail with an emphasis on safety and data integrity.
  • Problem-solving mindset and calmness under pressure during in-test anomalies.
  • Collaboration and teamwork across engineering, maintenance, and operations groups.
  • Time management and ability to prioritize multiple concurrent test campaigns.
  • Adaptability to evolving test requirements and last-minute engineering requests.
  • Mentoring and knowledge transfer abilities to train junior technicians.
  • Customer-facing professionalism during witnessed tests and certification activities.
  • Organizational skills for maintaining logs, checklists, and test artifacts.
  • Continuous improvement orientation with the ability to propose pragmatic process changes.

Education & Experience

Educational Background

Minimum Education:

  • Associate degree in Aviation Maintenance Technology, Turbine Engine Technology, or Mechanical Engineering Technology; or equivalent military experience (aircraft propulsion/engine specialist).

Preferred Education:

  • Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or related technical field preferred for test engineering progression.
  • Certifications: FAA A&P license (for US roles), safety certifications (OSHA), and specialized training in DAQ/Instrumentation.

Relevant Fields of Study:

  • Aerospace Engineering
  • Mechanical Engineering
  • Aviation Maintenance Technology
  • Turbine/Powerplant Technology
  • Instrumentation and Controls

Experience Requirements

Typical Experience Range: 2 – 8 years of progressive hands-on engine testing or propulsion maintenance experience; 5+ years preferred for senior roles.

Preferred:

  • Demonstrated experience operating production or development engine test cells, capturing performance maps and supporting certification test campaigns.
  • Experience working with OEM engine models and test protocols, with a record of participating in witnessed customer or regulatory tests.
  • Proven track record of executing safe hot-fire tests, performing complex instrumentation installs, and delivering high-quality technical reports.
Explore More Careers