Valves Assembly & Testing Engineer

Valves Assembly & Testing Engineer is responsible for precision assembly, calibration, and qualification testing of cryogenic and other liquid-propulsion valves used in rocket engines and ground-support systems. This role requires deep understanding of cryogenic fluids (LOX, LHe, LCH4), high-pressure systems, aerospace materials, and stringent quality and safety standards. The engineer ensures that each valve meets mission-critical requirements for reliability, leak-tightness, and performance under extreme conditions.

Key Responsibilities

1. Valve Assembly

• Assemble cryogenic isolation valves, pneumatic injection valves, flow control valves, solenoid valves, check valves, etc. according to the mission requirements.
• Work with precision components including seals, soft goods, PTFE seats, cryo-compatible lubricants, and exotic alloys (Inconel, Monel, titanium, stainless steel).
• Perform lapping, alignment, torquing, and precision fitment to ensure zero-leak performance at cryogenic temperatures.
• Assemble actuators (pneumatic, electric, or hydraulic) and integrate sensors/feedback mechanisms.
• Collaborate with design engineers to review valve design requirements and recommend improvements.
• Provide feedback on recurring issues, material performance at cryogenic temperatures, and assembly optimizations.
• Assist in developing new test setups, fixtures, and validation procedures.

2. Valve Testing & Qualification

• Conduct cryogenic tests using LOX, LN2, LNG etc. under controlled safe-handling procedures.
• Perform high-pressure and proof-pressure tests per aerospace propulsion standards.
• Execute functional tests including flow test, response time, cracking pressure, and actuation cycle tests.
• Conduct helium leak detection tests (mass spectrometer leak detection) for ultra-tight tolerances.
• Evaluate performance under thermal cycling, vibration loads, and simulated launch conditions.
• Follow strict safety protocols for handling cryogenic fluids, high-pressure systems, and rocket engine propellants.
• Ensure compliance with aerospace safety guidelines and facility-specific hazardous operations procedures.

3. Quality Assurance & Documentation

• Inspect and verify incoming components for aerospace standards (material certifications, dimensional tolerances, NDT reports).
• Document all assembly steps, test results, and calibration data in accordance with aerospace quality systems.
• Prepare detailed test reports for engineering, quality, and mission assurance review.
• Support Failure Mode Analysis (FMEA), Root Cause Investigations (RCA), and corrective action plans.

Experience & Skills

• 2 to 5 years in aerospace, cryogenic systems, propulsion, or high-precision valve assembly/testing.
• Experience with cryogenic fluids (LOX, LH2, LN2, LCH4) is highly desirable.
• Strong knowledge of cryogenic materials, thermal contraction effects, and fluid dynamics.
• Familiarity with aerospace standards (AS9100, MIL-specs, NASA, or ISRO propulsion guidelines).
• Skilled in using helium leak detectors, cryogenic test benches, pressure regulators, and precision gauges.
• Ability to read aerospace drawings, schematics, P&IDs, and tolerance stack-ups.
• Hands-on experience with torque tools, clean-room assembly, and contamination control.