Welding Engineer

Job Summary

We are seeking a hands-on and experienced Welding Engineer to own the development, qualification, and continuous improvement of our welding processes for spiral-welded wind-tower manufacturing. This role is crucial for ensuring our welding operations meet and exceed the stringent requirements of AWS D1.1, ISO 9001, and key customer specifications. You will act as the bridge between engineering and production, driving the creation of robust, efficient, and high-quality welds across all our production lines.

Key Responsibilities

• Process Development & Qualification: Develop, document, and qualify critical welding procedures, including WPS (Welding Procedure Specifications) , PQRs (Procedure Qualification Records) , and WPQRs for Submerged Arc Welding (SAW), GMAW, FCAW, and other automated processes.

• Troubleshooting & Problem-Solving: Serve as the primary technical expert for diagnosing and resolving complex weld defects like porosity, incomplete fusion, and inconsistencies. Utilize root cause analysis tools (e.g., 8D, 5-Why) to implement effective and permanent corrective actions.

• Process Optimization: Lead welding trials and parameter optimization using advanced equipment like the Lincoln Power Wave AC/DC 1000. Analyze waveform and process data to enhance arc stability, control heat input, and maximize deposition efficiency.

• Collaboration & Support: Partner with Manufacturing Engineering to develop and implement fixtures, manipulators, and robotic welding cells. Collaborate with the Quality department to resolve Non-Conformance Reports (NCRs), validate repair procedures, and ensure inspection plans are robust.

• Team Leadership & Training: Train, qualify, and mentor welders, maintaining all welder performance and continuity records to ensure a highly skilled workforce.

• Continuous Improvement: Drive initiatives to improve key performance indicators ( KPIs ) such as throughput, cost-per-weld, and first-pass yield using Lean and Six Sigma methodologies.

• Design & Quoting: Provide expert welding input during product design reviews, advising on joint configurations, weld symbols, and overall manufacturability to ensure designs are optimized for production.

Required Qualifications

• Bachelors Degree in Welding Engineering, Materials Science, or a related technical field; OR 15-20 years of directly relevant, hands-on experience in a similar role.

• Must have extensive hands-on experience diagnosing and solving issues with weld defects in a heavy fabrication environment.

• Proven experience overseeing a welding program in a manufacturing shop setting .

• Demonstrated success in developing and qualifying PQRs and WPSs for Submerged Arc Welding (SAW) .

• Experience managing and tracking welding KPIs to drive process improvements.

• Strong working knowledge of AWS D1.1 standards.

• Proficient computer skills , including MS Office and CAD software (SolidWorks or similar).

Preferred Qualifications

• AWS Certified Welding Inspector ( CWI ), Certified Welding Educator ( CWE ), or Senior Certified Welding Inspector ( SCWI ) certification.

• Experience with wind-tower OEM specifications (e.g., GE Vernova, Vestas).

• Familiarity with advanced inspection systems (e.g., photogrammetry) and statistical process control (SPC).

• Lean Six Sigma Green Belt certification.

• Proficiency with ERP/PLM systems (e.g., SAP, Oracle).

Soft Skills

• Strong shop-floor presence with a hands-on, can-do attitude.

• Excellent analytical, problem-solving, and technical documentation abilities.

• Ability to communicate effectively and lead through influence across all levels of the organization.

• Highly organized and self-directed, with a proven ability to manage multiple priorities in a fast-paced manufacturing environment.

Physical Requirements

• Ability to work in a production setting, which includes standing, walking, climbing ladders, and lifting up to 50 lbs.

The target hiring compensation range for this role is $132k to $142k. Compensation is based on several factors including, but not limited to education, relevant work experience, relevant certifications, and location.

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