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Key Responsibilities and Required Skills for Jet Test Engineer

💰 $ - $

AerospaceEngineeringTestingPropulsion

🎯 Role Definition

The Jet Test Engineer is responsible for planning, executing and documenting ground and flight tests of jet engines and propulsion systems to validate performance, reliability, safety, and compliance with regulatory requirements. This role combines deep technical knowledge of gas turbine engines and test instrumentation with hands-on test cell operations, root-cause troubleshooting, data analysis, and cross-functional coordination with design, manufacturing, and certification teams. The ideal candidate has demonstrated experience with engine test cells, data acquisition systems, test safety protocols, and a track record of delivering actionable engineering conclusions from complex test campaigns.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Test Technician or Test Cell Operator (Engine Test)
  • Junior Aerospace Engineer (propulsion or systems)
  • Field Service Engineer (turbine engines)

Advancement To:

  • Senior Jet Test Engineer / Lead Test Engineer
  • Propulsion Test Team Lead or Test Laboratory Manager
  • Flight Test Engineer (senior) or Propulsion Systems Engineer

Lateral Moves:

  • Engine Design / Performance Engineer
  • Reliability & Safety Engineer (propulsion)
  • Certification/Regulatory Compliance Engineer

Core Responsibilities

Primary Functions

  • Plan, develop and execute complex engine ground test programs (prototype and production turbines) including test objectives, success criteria, resource requirements, safety plans, instrumentation lists and run schedules to validate engine performance, fuel consumption, emissions and endurance.
  • Configure, install and verify test instrumentation and sensor suites (pressure transducers, thermocouples, strain gauges, accelerometers, high-speed pressure probes) and ensure proper routing, calibration and signal integrity for high-fidelity data capture during engine runs.
  • Design and build or adapt test rigs, engine mounts, inlets, exhaust diffusers and auxiliary systems (fuel, oil, hydraulics, pneumatic purges) required for steady-state, transient, and life-cycle engine testing within the test cell or test stand.
  • Operate engine test cells and coordinate ground-test activities, including engine start/shutdown sequences, emergency stop procedures, flameout and relight sequences, bleed air management and safe handling of hot sections and rotating machinery.
  • Develop detailed test procedures, scripts and checklists for ground and flight tests; brief test teams and stakeholders; perform pre-test safety and readiness reviews and obtain sign‑offs from engineering, operations and safety authorities.
  • Configure and run data acquisition systems (e.g., LabVIEW, DEWESoft, NI hardware, real-time DAQ) and ensure synchronized multi-channel logging of thermodynamic, mechanical and environmental signals at high sampling rates for performance and transient analysis.
  • Analyze test data using engineering tools and languages (MATLAB, Python, Excel, R) to extract performance metrics—thrust, TSFC, EGT margins, compressor maps, surge/stall margins—and produce clear technical reports with plots, observations and engineering recommendations.
  • Identify, investigate and lead root-cause analysis of anomalies discovered during testing (vibrations, contamination, compressor surge, combustion instabilities, oil system anomalies) and propose corrective design changes, test modifications or maintenance actions.
  • Coordinate with avionics, controls and electronic engine control (EEC/FADEC) teams to validate software updates, control laws, and health monitoring logic during test events and flight test scenarios.
  • Prepare and maintain accurate test documentation, run cards, calibration records, instrumentation lists and test logs to support traceability and certification evidence for FAA/EASA and internal quality audits.
  • Ensure compliance with regulatory, environmental and safety standards (FAA/EASA regulations, OSHA, company HSE policies) during fuel handling, hot-section operations, high-speed rotating machinery tests and high-temperature exposure.
  • Lead integration, checkout and verification testing of engine accessories and subsystems (fuel control units, igniters, starters, hydraulic pumps, gearboxes) under representative thermal and mechanical loads within the test environment.
  • Work closely with suppliers and manufacturing to plan component-level qualification tests (turbine blades, combustor liners, bearings) and coordinate non-destructive inspection (NDT) and life‑cycle testing campaigns.
  • Support flight test planning and participate as ground/flight test engineer to validate engine behavior in real flight envelopes; monitor telemetry, provide real-time decision support and write post-flight analyses.
  • Develop and execute endurance and durability tests to characterize life-limited parts and demonstrate margins for creep, fatigue, thermal degradation and corrosion under sustained operational profiles.
  • Implement and maintain test cell safety systems and procedures including remote shutdowns, fire suppression, exhaust capture, noise mitigation and environmental controls to protect personnel and facilities.
  • Mentor and provide technical direction to test technicians, junior engineers and contractors; delegate tasks and review test results to ensure alignment with engineering objectives and quality standards.
  • Maintain and calibrate test equipment, DAQ channels, sensors and transducers; manage spare parts, tooling and consumables inventories to support continuous test operations.
  • Estimate test campaign budgets, resource needs and timelines; track execution against plans and provide status updates to program management, recommending mitigation when risks arise.
  • Collaborate cross-functionally with propulsion design, aerodynamicists, structural engineers, materials scientists and certification specialists to translate test results into design improvements, product acceptance and field reliability actions.
  • Evaluate and implement new test methods, instrumentation technologies, and data analytics techniques (machine learning applied to condition monitoring) to increase test throughput, insight and predictive capabilities.

Secondary Functions

  • Support ad-hoc technical investigations, engineering change requests (ECRs) and corrective action reports arising from in-service engine data or production anomalies.
  • Contribute to continuous improvement of test processes, cell utilization and safety culture by participating in lessons‑learned reviews, tooling standardization and test automation initiatives.
  • Assist program managers with vendor evaluations, statement-of-work reviews and acceptance testing of supplier-provided components or subsystems.
  • Participate in failure mode and effects analysis (FMEA), reliability growth testing and product qualification reviews to support certification packages.
  • Provide technical input to training materials and standard operating procedures for test cell personnel and field engineers.

Required Skills & Competencies

Hard Skills (Technical)

  • Gas turbine engine testing and performance analysis (turbofan, turboprop, turbojet) including thrust measurement, TSFC calculation and thermodynamic cycle understanding.
  • Test cell operations and safety: engine start/shutdown sequences, hot section handling, fire suppression systems and test cell ventilation/exhaust management.
  • Test instrumentation and data acquisition: experience with LabVIEW, NI DAQ hardware, DEWESoft or equivalent high-speed acquisition systems and channel synchronization.
  • Signal conditioning and sensor familiarity: pressure transducers (piezoelectric, piezoresistive), thermocouples, RTDs, strain gauges, accelerometers and signal filtering techniques.
  • Data analysis and scripting: MATLAB, Python (NumPy, pandas, SciPy), R or proprietary analysis tools for processing large test datasets and automating post‑test workflows.
  • Control systems and FADEC/EEC interface testing, including telemetry, hardware-in-the-loop (HIL) setups and control software validation.
  • Vibration, modal and structural testing concepts including NVH tools, strain measurement and root-cause identification of rotating system anomalies.
  • Environmental and endurance testing: thermal cycling, salt-fog, altitude chamber testing and component life‑cycle qualification procedures.
  • CAD and system integration understanding (SolidWorks, CATIA) to support test fixture design, interface drawings and mechanical modifications.
  • Calibration and metrology: maintaining calibration chains, uncertainty analysis, and traceability of test sensors and instrumentation to national standards.
  • Knowledge of regulatory and certification frameworks (FAA, EASA, DO-160 for environmental conditions, MIL-STD as applicable).
  • Proficiency with telemetry protocols and standards (ARINC, CANbus) and experience with real-time data streaming and logging.
  • Fuel system and fluid dynamics understanding (fuel pumps, filters, metering units) and safe handling of aviation fuels during test operations.
  • Test planning and project management tools: MS Project, JIRA or equivalent for tracking test schedules, issues and change control.
  • Familiarity with non-destructive inspection (NDT) techniques—eddy current, ultrasonic, borescope inspection—to assess components post-test.

Soft Skills

  • Strong analytical and problem-solving skills with attention to detail for interpreting complex multi-channel datasets and drawing actionable conclusions.
  • Excellent verbal and written communication: able to write clear test reports, present technical findings to engineers and managers, and prepare certification evidence.
  • Collaborative team player comfortable working in cross-functional and multidisciplinary teams including manufacturing, supply chain and certification groups.
  • Decisive under pressure with proven ability to make safe, well-documented decisions during live testing and flight operations.
  • Time management and organizational skills to manage multiple concurrent test campaigns and tight schedules.
  • Mentoring and leadership capability to develop junior engineers and technicians in test methodologies and safety practices.
  • Adaptability and continuous-learning mindset to adopt new instrumentation, data analysis techniques and industry best practices.
  • Strong customer focus when interfacing with internal stakeholders, suppliers or airline/operator customers during acceptance testing.
  • Conflict resolution and negotiation skills for coordinating test priorities, resource allocation and scope trade-offs.
  • Ethical and safety-first attitude with commitment to compliance, documentation and regulatory requirements.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, Aeronautical Engineering, or equivalent technical discipline.

Preferred Education:

  • Master’s degree in Aerospace/Mechanical Engineering, Propulsion, Thermal Sciences, or relevant advanced degree.
  • Certifications in project management (PMP), quality (AS9100) or specific test instrumentation training (National Instruments, LabVIEW).

Relevant Fields of Study:

  • Aerospace Engineering
  • Mechanical Engineering
  • Thermodynamics / Propulsion
  • Controls and Instrumentation Engineering
  • Materials Science (for durability & life testing)

Experience Requirements

Typical Experience Range:

  • 3–10+ years of relevant experience in jet engine/propulsion testing, test cell operations or flight test engineering.

Preferred:

  • 5+ years of direct experience with gas turbine engine testing and data acquisition.
  • Hands-on experience with engine test cells, flight test support, FADEC integration, and certification test programs (FAA/EASA).
  • Demonstrated history of leading test campaigns, troubleshooting complex engine issues, and producing certification-quality deliverables.
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