{"id":763858,"url":"https://alion.io/job/arborenergy-sr-heat-exchanger-engineer","title":"Sr. Heat Exchanger Engineer","company":{"id":669165,"name":"Arbor Energy","domain":"arborenergy.com","url":"https://alion.io/company/arborenergy","size_band":null,"is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"B","score":70,"open_postings":16,"ghost_share":0.5,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-30T05:48:23Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["El Segundo, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":165000,"max":180000,"currency":"USD","period":"year","gross":null,"usd_annual":180000},"salary_estimate":null,"experience_years_min":6,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"MATLAB","optional":false},{"name":"Python","optional":false}],"status":"live","first_seen_at":"2026-05-05T15:19:30Z","employer_posted_date":"2026-10-02","last_verified_at":"2026-10-31T02:39:24Z","board_verified":true,"closed_at":null,"days_open":178,"trust":{"level":"ghost","repost_count":0,"flags":["stale","company_stale"],"days_open":176},"description":"About Us\nAt Arbor Energy & Resources Corporation (\"Arbor Energy\"), we’re creating technology to power our lives while protecting the planet that sustains them. Our advanced power systems deliver clean, reliable baseload electricity with zero operating emissions-modular, fuel-flexible, and engineered for the realities of today’s energy demand. At the core is a supercritical CO₂ turbine with integrated carbon capture, designed to bring carbon-neutral power online quickly at meaningful scale. \nOur team includes aerospace engineers, combustion experts, and systems thinkers with a shared goal: to build technology worthy of the world we want to live in. While many of us began our journeys looking to the stars, we’re applying that expertise here at home to deliver dependable, emission-free baseload power and a future of lasting abundance. \nIf you share our values and are drawn to rigorous work with lasting impact, we’d love to learn more about you. Come build what the future will run on.\nSteward our planet: We build for tomorrow, ensuring every bolt we tighten and every hand we lend leaves our environment stronger than we found it.\nLead with Love: We champion the success of our people, partners, and planet, nurturing excellence through camaraderie and rigor.\nExplore the Uncharted: We embrace the unknown with curiosity, using courage and discipline to transform uncertainty into opportunity.\nRole Overview\nWe're looking for a Sr. Heat Exchanger Engineer to own the design, specification, and development of the compact heat exchangers at the heart of Arbor's supercritical CO₂ power system-the high- and low-temperature recuperators that set plant efficiency, and the coolers around them. You'll lead technical engagement with our heat exchanger suppliers, develop and test additively manufactured and diffusion-bonded designs in high-temperature nickel alloys, and own the thermal and mechanical case for the hardware we put into service. You'll work closely with cycle analysts, mechanical and pressure vessel engineers, manufacturing, and test engineers in a fast-paced, hands-on R&D environment. This is a rare opportunity to apply deep thermal-fluids and manufacturing expertise to climate-impactful technology at the frontier of power generation.\nA power-industry background is not required. Engineers who have designed, built, and tested high-performance thermal hardware in aerospace, propulsion, or advanced manufacturing are encouraged to apply.\nThis is an onsite opportunity in our El Segundo, CA office. \nResponsibilities\nOwn the thermal-hydraulic design of compact heat exchangers across the Arbor power system-high- and low-temperature recuperators, precoolers, and heaters-from conceptual sizing through detailed design, balancing effectiveness, pressure drop, mass, and cost.\nServe as technical lead with suppliers of advanced compact heat exchangers, including additively manufactured and printed circuit (diffusion-bonded) units: define requirements and specifications, lead design reviews, and own qualification and acceptance testing.\nLead in-house design and development of additively manufactured heat exchangers in high-temperature nickel alloys (e.g., Inconel 625, Haynes 282), applying design for additive manufacturing (DfAM) to channels, headers, and manifolds.\nPlan and run print and flow trials-from coupons through subscale cores-to characterize geometry, surface finish, and process effects, and anchor thermal-hydraulic and pressure drop models to the data.\nOwn the thermal-mechanical life case for high-temperature heat exchangers-pressure containment, thermal transients, creep, and fatigue-working with mechanical and pressure vessel engineers on ASME code compliance.\nPlan and execute thermal and hydraulic performance testing on development and plant hardware: define instrumentation, write test procedures, lead data reduction, and close the loop between test results and design.\nSpecify and technically manage conventional heat exchangers (shell-and-tube, air-cooled) per TEMA and API 661 as balance-of-plant needs arise.\nGenerate and maintain the full engineering documentation package: thermal and mechanical calculation packages, drawings, material and process specifications, and test reports.\nRequirements\nBachelor's degree in Mechanical, Chemical, Aerospace, or related Engineering field.\n6+ years of experience designing, building, and testing high-performance thermal-fluid hardware-heat exchangers, recuperators, precoolers, regeneratively cooled components, or similar.\nDemonstrated thermal-hydraulic design of compact heat transfer hardware-additively manufactured, printed circuit, plate-fin, microchannel, or regeneratively cooled-including channel geometry selection for performance, pressure drop, and manufacturability.\nHands-on manufacturing experience with processes that form internal flow passages-metal additive manufacturing (laser powder bed fusion or similar), vacuum brazing, or diffusion bonding-including process troubleshooting, inspection, and defect disposition.\nTrack record of taking full-scale hardware-flight, production, or industrial-from design through fabrication and test, and using test data to correct your models and designs.\nAbility to build first-principles thermal-hydraulic models (e.g., segmental ε-NTU with variable fluid properties) in Python, MATLAB, or similar.\nWorking knowledge of pressure-containing and elevated-temperature structural design-thermal stress, creep, and fatigue-sufficient to drive a life assessment with support from specialists.\nTrack record of making consequential technical decisions with incomplete information, owning the outcome, and moving fast in a small team.\nPreferred Qualifications\nExperience with supercritical CO₂ or other supercritical or dense-phase fluids, including cryogenic propellants.\nExperience designing or qualifying printed circuit or other diffusion-bonded heat exchangers.\nExperience qualifying AM parameter sets, HIP and heat treatment, and powder removal for parts with internal passages.\nExperience specifying conventional heat exchangers per TEMA and API 661; proficiency with HTRI or equivalent.\nFamiliarity with ASME Boiler and Pressure Vessel Code Section VIII as applied to heat exchangers.\nBackground in startup, aerospace, or first-of-a-kind hardware development environments.\nBenefits & Compensation\nPre-IPO stock options\nMedical, dental, and vision insurance (Arbor covers 90% for employees)\nBasic life insurance fully covered\nHealth savings account (HSA) with matching\nFlexible savings account (FSA)\nUnlimited PTO \n12+ company holidays, including Earth Day! \n401(k)\nCommuter benefits\nAnnual learning and development stipend\nAnd more!\nBase Pay: $165,000 - $180,000 USD/year. The salary is subject to the applicant's skills, qualifications, experience, and geographic location.\nOur Commitment\nArbor Energy is proud to be an equal opportunity employer. We evaluate qualified applicants without regard to race, religion, national origin, gender identity or expression, sexual orientation, age, marital or veteran status, disability, or any other protected characteristic under applicable law. Solving global energy challenges requires a wide range of perspectives and experiences, and we are committed to building a team that reflects the world we serve.\nOur hiring process is designed to be accessible, fair, and focused on the work that matters most for this role. 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