CFD Engineer (CAE) - Propulsion and Battery Systems

Description
Role
As a CFD Engineer - Propulsion and Battery Systems, you will lead DFMEA-driven 3D
Computational Fluid Dynamics (CFD) analysis at the component, subsystem, and
system level to optimize thermal performance and system reliability across GM propulsion
systems. Operating within a DFMEA-centric environment, you will use virtual engineering
to identify failure modes, evaluate severity/occurrence risks, and drive robust risk
mitigation strategies for propulsion systems, specifically battery and power electronics
thermal performance, durability and safety requirements.
Work Arrangement
Hybrid work position: This position does not require an employee to be on-site full-time to
perform most effectively. The employee's role enables them to work at a GM facility or off-
site as frequently as needed or desired.
Primary Responsibilities
• Perform DFMEA-aligned 3D CFD analysis focusing on high-voltage battery systems
and power electronics to identify and mitigate critical thermal failure modes at the
cell, module, pack, and system level.
• Simulate and quantify battery Thermal Runaway Propagation (TRP), venting gas
dynamics, and safety physics under severe abuse scenarios to validate DFMEA
mitigation designs, barrier integrity, and failure containment controls.
• Lead thermal risk assessments during early architecture definition and concept
selection using rapid CFD trade studies to eliminate high-risk failure modes prior to
design freeze.
• Correlate virtual failure mode predictions with physical test and validation data to
ensure simulation fidelity in predicting real-world failure thresholds and reliability
margins.
• Clearly and effectively communicate analysis plans, assumptions, and results to
internal and external stakeholders using presentations, reports, and design reviews.
• Meet or exceed timing, quality, and cost targets within structured product
development processes.
• Participate in and/or lead benchmarking and advanced methods activities to
continuously improve GM's virtual engineering capabilities in CFD and multi-
physics analysis.
Required Skills and Experience
• 5+ years of experience with simulation, design, testing, or release of propulsion-
related systems (e.g., engines, transmissions, e-drive units, batteries, power
electronics, thermal management systems).
• Hands-on experience with at least one commercial 3D CFD software package
(e.g., STAR-CCM+, Simerics-MP+, Fluent, or equivalent).
• Demonstrated understanding of heat transfer and fluid mechanics (conduction,
convection, radiation, pressure loss, turbulence, etc.) applied to real engineering
systems.
• Familiarity or practical experience with vehicle propulsion system design,
operation, or testing.
• BS in Mechanical or Aerospace Engineering (or closely related field) required.
Preferred Skills and Experience
• 5+ years of advanced experience with 3D CFD thermal and fluid analysis
specialized for battery pack and module systems.
• Experience in modeling battery Thermal Runaway Propagation (TRP) and gas
venting dynamics under severe thermal abuse and cell failure conditions.
• Experience with electro-thermal multi-physics coupling, integrating
electrochemical heat generation models with 3D CFD for cell characterization,
module, and pack simulations.
• Expertise in Artificial Intelligence (AI), Machine Learning (ML), and Reduced
Order Modeling (ROM) for rapid thermal prediction, digital twins, and real-time
CFD surrogate modeling
GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc.)
This role is categorized as hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}.
Relocation benefits are available for candidates who qualify under company policy.
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