Senior Process Engineer- Nickel Plating/ Electroplating in Baltimore, Maryland at SQA Services

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. This is a short-term (2-week) consulting postition working full-time hours on the first shift.

Technical Process Assessment
• 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
Racking & Fixturing Evaluation
• 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
Defect Investigation & Root Cause Analysis
• 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
Process Validation & Trial Support
• 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
Supplier Technical Support
• 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
Documentation & Reporting
• 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

Candidates should possess strong working knowledge of:

Aerospace Electroplating Processes
• 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
Racking & Current Distribution
• 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
Inspection & Verification
• Plating thickness measurement methods
• XRF systems
• Cross-sectional analysis
• Measurement system considerations
• Inspection methodology evaluation
• Interpretation of plating specifications and acceptance criteria
Aerospace Manufacturing Environment
• 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 manufacturing

• 10+ years of aerospace electroplating or special process experience
• Experience supporting aerospace OEMs or Tier 1 suppliers
• NADCAP special process experience strongly preferred
• Experience with nickel plating process troubleshooting and remediation
• Experience with complex machined aerospace hardware
• Experience supporting supplier recovery activities
• Strong technical writing and reporting capabilities
• Ability to work independently onsite at supplier facilities

Experience supporting one or more of the following industries is preferred:

• Aerospace
• Space launch systems
• Defense
• Precision machining
• Flight hardware manufacturing
• High-reliability manufacturing environments

• Strong technical troubleshooting capability
• Hands-on process evaluation mindset
• Ability to communicate effectively with both executive leadership and shop floor personnel
• Objective and data-driven decision making
• Collaborative but technically assertive approach
• Ability to rapidly assess manufacturing risk and process maturity

• Significant onsite supplier support activities may be required
• Travel to customer and supplier manufacturing locations required
• Short-duration intensive technical assessments and remediation activities typical