Engineering Intern - Aerospace Coating technology

Internship/Thesis Opportunity: Process Optimization in Aerospace Coating Technology

Project Title: UHPW – A Necessity or a Waste?
Location: Chromalloy Holland B.V.
Start Date: September 2025
Duration: 8–12 months
Level: Academic (Bachelor/Master)
Department: Engineering / Quality / Operations

About Chromalloy

Chromalloy Holland is a global leader in the repair and manufacturing of components for aero engines and industrial gas turbines. Our core product line includes High Pressure Turbine (HPT) shrouds, which undergo complex repair processes involving welding, grinding, EDM, coating, and heat treatment.

Project Background

In the current process, the gas path surface of HPT shrouds is grit blasted to create the necessary roughness for thermal spray coating (HVOF). However, this step often results in embedded Al₂O₃ particles, which can compromise coating adhesion and act as crack initiation sites. To mitigate this, an Ultra High Pressure Waterjet (UHPW) cleaning step is used—but this adds time, cost, and complexity to the process.

The UHPW equipment is aging and due for replacement, prompting the question: Is UHPW truly necessary, or can it be eliminated through process optimization?

Project Objective

The goal of this project is to eliminate the UHPW cleaning step from the HPT shroud repair process without compromising coating quality or process reliability. This includes:

• Investigating industry standards and best practices
• Optimizing grit blasting parameters to reduce embedded particles
• Exploring alternative surface preparation methods (e.g., grinding-only)
• Evaluating alternative materials (e.g., SiC) and their behavior post-heat treatment
• Assessing bonding quality and coating performance

Your Role

As the project lead (intern or thesis student), you will:

• Conduct a literature review and benchmark industry practices
• Design and execute test series in collaboration with operations and engineering
• Analyze surface roughness, embedded particle counts, and coating adhesion
• Apply the DMAIC methodology (Define, Measure, Analyze, Improve, Control)
• Present findings and recommendations to stakeholders

Support & Supervision

• Sr. SME Engineering: Ron van Gestel
• Process Specialist: Seda Tüzemen
• OPS Supervisors & Operators: Sam van der Weegen and team
• Project Sponsors: Wesley Blommensteijn, Sam van der Weegen

What We Offer

• A challenging and impactful assignment with real-world application
• Hands-on experience in a high-tech aerospace manufacturing environment
• Mentorship from experienced engineers and specialists
• Opportunity to contribute to process innovation and cost reduction
• A mix of desk research and hands-on operational testing

Scope

In Scope: HPT shrouds and tip shoes (various configurations)
Out of Scope: Other parts, pre-TS preparation, post-TS diffusion heat treatment

Interested?

Apply now and help shape the future of aerospace component repair.
📧 Apply now via the website 
🌐 Learn more at: chromalloy.com