Senior Manager - R&D Casting

JOB PURPOSE:

Lead and direct the Alloy & Process Development function across four specialist teams —

Alloy Development, Process Development, Material Characterization & Lab, and Application &

Customer Engineering. The role owns the full development journey for aluminium alloys, from

early-stage computational research and laboratory exploration through to process

industrialisation and validation in real customer parts and applications. The role is accountable

for ensuring that promising alloy concepts are systematically advanced, de-risked, and proven

at each stage of maturity until they are ready for commercial deployment.

KEY ACCOUNTABILITIES:

Strategic Leadership: Set and drive the R&D strategy for Alloy & Process Development,

defining the innovation roadmap and ensuring a healthy pipeline of alloy programmes at every

stage of development — from early concept exploration through to customer-ready validated

solutions

Alloy Development: Oversee the earliest stages of alloy design — using computational tools

and small-scale laboratory trials to identify, screen, and validate promising compositions before

committing to larger-scale development. Ensure only alloys that meet defined performance,

practicality, and sustainability gates are advanced to the next stage.

Process Development: Take alloys proven at lab scale and ensure they are successfully

translated into robust, repeatable industrial processes across casting, forming, and heat

treatment. Drive the transition from controlled pilot conditions to full production readiness,

closing the gap between what works in the lab and what works on the shop floor.

Material Characterization & Lab: Provide the evidential backbone for all development

decisions — delivering accurate, traceable testing and validation data at every stage of maturity,

from early microstructural screening through to full mechanical, corrosion, and durability

qualification in compliance with ISO/ASTM standards.

Application & Customer Engineering: Own the final stages of the development journey —

validating alloys and processes against real-world customer requirements, running application-

specific simulations and part-level tests, and delivering the qualification packages needed for

Original Equipment Manufacturer (OEM) approval and commercial release.

People & Capability: Recruit, develop, and retain a high-performing multidisciplinary team

capable of operating effectively across the full development spectrum. Build a culture of

technical excellence, collaboration, and structured stage-gate thinking.

Knowledge Management: Ensure all outputs at every stage of development — simulations,

trial data, recipes, datasheets, and validation reports — are systematically documented in a

shared digital knowledge base, enabling informed go/no-go decisions and institutional learning.

Financial Management: Own and manage the Alloy & Process Development function’s

operating and capital budget. Prepare and present budget proposals, monitor spend, and take

corrective action on variances. Ensure investment is appropriately staged — with early-phase

programmes resourced efficiently and increased commitment reserved for alloys that have

cleared defined development gates. Approve purchase orders and supplier contracts within

delegated authority and support business cases for significant capital investments.

Intellectual Property Management: Oversee identification, protection, and management of all

intellectual property generated across Alloy & Process Development — alloy compositions,

process innovations, computational models, and application methods. Establish a systematic

review process to capture and assess patentable developments as they emerge through the

pipeline. Work with legal counsel on filings, ensure all staff understand intellectual property

obligations, manage intellectual property risk in collaborative programmes, and maintain a live

register of the centre’s patent portfolio.

Development of UAE Nationals: Champion Emiratisation by identifying suitable roles across

the full range of functions — from lab technician and characterization roles through to

engineering and specialist positions. Partner with HR on graduate and early-career

programmes, mentor and coach UAE National employees, and set measurable Emiratisation

targets reported to senior leadership. Build relationships with UAE universities and government

talent initiatives to develop a sustainable pipeline of Emirati R&D professionals.

AUTHORITY/ DECISION MAKING:

Direct R&D programmes, set priorities, and allocate resources across all four functions.

Approve progression of alloys from early laboratory exploration through to pilot scale, billet

casting, and production trials — acting as the principal gate-keeper at each development stage.

Approve process changes, equipment trials, and external technical partnerships.

Sign off validation packages, qualification reports, and datasheets before external release to

customers or Original Equipment Manufacturer (OEM).

Approve capex and opex within delegated budget limits.

Escalate significant commercial commitments or cross-functional strategy decisions to the

relevant personnel.

QUALIFICATIONS & SKILLS:

Minimum Qualifications: Degree in Materials Science, Metallurgy, or Mechanical Engineering;

postgraduate qualification (MSc/PhD) strongly preferred. 10+ years in aluminium R&D or

metallurgical process engineering, with 3–5 years in a leadership role and demonstrable

experience taking alloys from early research through to industrial qualification and customer

validation.

Technical Skills: Strong knowledge of aluminium metallurgy across casting, extrusion, and heat

treatment. Familiarity with CALPHAD tools (Thermo-Calc, JMatPro), process simulation (Finite

element method, Computational fluid dynamics, digital twins), and characterization techniques

(Optical emission spectrometry, scanning electron microscope, X-Ray diffraction). Solid

understanding of application validation including forming, joining, crash, and fatigue — and what

it takes to prove an alloy in a real part under real conditions.

Leadership and Management: Proven ability to lead multidisciplinary technical teams across

the full development lifecycle. Strategic thinker with experience managing structured, stage-

gated R&D programmes and strong stakeholder management across customers, Original

Equipment Manufacturer (OEM)., suppliers, and senior leadership.

Personal Attributes: Collaborative and inclusive with high technical integrity. Clear

communicator across technical and non-technical audiences. Practical and results-oriented, with

the judgement to know when an alloy is ready to progress and when it is not. Committed to

sustainability and knowledge sharing.