Sr. Weld Engineer

Position Summary

The Weld Engineer is responsible for developing, implementing, and optimizing welding processes that ensure product quality, compliance, and manufacturing efficiency. This role provides technical leadership for weld procedure development, weld schedule creation, qualification activities, and continuous improvement initiatives. The Weld Engineer works closely with Manufacturing, Quality, Engineering, Operations, and Estimating teams to support production of aerospace-grade components and assemblies while maintaining compliance with AS9100 and NADCAP requirements. This position also provides technical expertise to support customer quotations, manufacturability assessments, and new business opportunities.

Essential Duties and Responsibilities

• Develop, qualify, and maintain welding procedures and weld schedules for production and development programs.
• Support manufacturing processes involving nickel alloy sheet metal, forgings, and complex fabricated assemblies.
• Provide technical expertise in GTAW (TIG), GMAW (MIG), resistance welding, laser welding, and other applicable joining processes.
• Establish process parameters and evaluate weld integrity through metallurgical analysis and destructive/non-destructive testing.
• Review engineering drawings, specifications, and customer requirements to determine welding and fabrication requirements.
• Lead root cause investigations and corrective actions related to weld quality issues.
• Collaborate with Quality and Production teams to improve weld performance, productivity, and first-pass yield.
• Support new product introduction activities, including weld process development and qualification.
• Prepare and maintain welding documentation, including work instructions, process specifications, qualification records, and manufacturing plans.
• Serve as a technical liaison with customers, suppliers, and regulatory agencies regarding welding processes and compliance requirements.
• Support internal, customer, and third-party audits, including AS9100 and NADCAP audits.
• Participate in continuous improvement initiatives focused on safety, quality, delivery, and cost.
• Support the Estimating and Business Development teams by reviewing customer drawings, specifications, and welding requirements to develop accurate labor, material, tooling, inspection, and processing estimates.
• Evaluate manufacturability and recommend cost-effective welding and fabrication solutions during the quotation process.
• Provide technical input regarding welding methods, fixture requirements, qualification requirements, production routing, and manufacturing risks to support customer proposals and quotes.
• Develop weld cycle time estimates, consumable requirements, and process cost models for nickel alloy sheet metal, forgings, and welded assemblies.
• Collaborate with Operations, Supply Chain, and Program Management teams to develop realistic manufacturing plans and cost estimates for new business opportunities.

Required Qualifications

• Bachelor's degree in Welding Engineering, Metallurgical Engineering, Materials Engineering, Mechanical Engineering, or related technical discipline.
• Minimum five (5) years of welding engineering experience in aerospace, defense, or high-reliability manufacturing environments.
• Demonstrated experience with nickel alloy sheet metal and forgings.
• Experience creating, developing, and maintaining weld schedules and welding procedures.
• Strong knowledge of welding metallurgy, heat input control, distortion management, and weld defect analysis.
• Experience supporting production welding operations and troubleshooting manufacturing challenges.
• Proficiency in reviewing engineering drawings, GD&T, and customer specifications.
• Experience supporting AS9100 quality management systems.
• Experience participating in or supporting NADCAP welding audits.
• Familiarity with AWS, ASME, AMS, and customer-specific welding requirements.
• Experience with weld qualification programs, process validation, and record retention requirements.
• Experience with standard report-writing tools (Word, Excel, PowerPoint) and ability to present complex metallurgical and engineering principles in clear language.
• Understanding of NDT methods including radiography, penetrant inspection, ultrasonic inspection, and visual inspection.
• Experience supporting estimating or proposal teams through technical review and manufacturing cost analysis.

Preferred Qualifications

• Certified Welding Engineer (CWE) or equivalent certification.
• Aerospace manufacturing experience.
• Knowledge of exotic alloys including Inconel, Hastelloy, Haynes, and other nickel-based alloys.
• Knowledge of Titanium and other refractory alloys.
• Experience with ERP/MRP systems and manufacturing documentation control.
• Lean Manufacturing and Six Sigma experience.
• Experience with robotic welding systems, weld automation, robotic programming, and process optimization.

Key Competencies

• Welding Process Development
• Weld Schedule Creation
• Metallurgical Sample Preparation and Analysis
• Ability to operate standard metallurgical laboratory equipment
• Root Cause and Corrective Action
• Failure Analysis
• AS9100 Compliance
• NADCAP Audit Support
• Aerospace Manufacturing
• Nickel Alloy Welding
• Estimating and Cost Analysis
• Manufacturing Process Development
• Continuous Improvement
• Technical Leadership
• Cross-Functional Collaboration
• Customer and Supplier Interface