Weld Process Engineer

Weld Process Engineer

Company: Coronal Technologies

Location: Long Beach, CA

Department: Engineering

Level: Mid to Senior / Individual Contributor Track

ITAR Notice: This position requires compliance with U.S. Government export control regulations (ITAR/EAR). Applicants must be a U.S. Person or otherwise legally authorized to access export-controlled technical data.

About Coronal Technologies

Coronal Technologies is developing next-generation spacecraft components using plasma arc additive manufacturing (PAM). We build flight-grade hardware — including titanium propellant tanks — using advanced wire directed energy deposition (DED) processes, enabling high-performance structures for the modern space economy. We are a fast-moving, technically rigorous team solving hard manufacturing problems that matter for the future of space access.

The Role

We are looking for a Weld Process Engineer to serve as the resident technical authority on weld pool dynamics, arc physics, and real-time process health across our plasma arc additive manufacturing (PAM) operations.

In this role, you will be the primary engineer responsible for "briefing in" welds—setting up, analyzing, and signing off on weld parameters before and during production builds. You will leverage active optical/camera monitoring systems to evaluate live weld bead behavior, diagnose process anomalies (such as bead wandering, stubbing, or instability), and establish real-time defect escalation thresholds for operators on the factory floor. You will work closely with manufacturing, hardware, process, and quality engineering to ensure every layer meets flight-grade standards.

Responsibilities

• Weld Briefing & Readiness: Brief in and sign off on weld execution plans for production and development builds (e.g., TIG, GTAW, PAM DED).
• Real-Time Process Monitoring: Serve as the subject matter expert on optical, camera, and sensor-based weld monitoring tools. Analyze live and recorded camera feeds to evaluate melt pool stability, arc consistency, and bead placement.
• Process Troubleshooting & Defect Root Cause: Diagnose active build issues—including bead wandering, wire stubbing/dripping, start/stop irregularities, and profile deviation—and define clear corrective actions.
• Operator Guidance & Escalation Criteria: Define clear visual inspection criteria and operational thresholds for floor operators and leads, ensuring consistent escalation without unnecessary production halts.
• Metallurgy & Procedure Development: Develop and qualify Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) for exotic aerospace metals (primarily Titanium Ti-6Al-4V).
• Hardware & Utility Servicing Oversight: Partner with hardware/ops teams to guide maintenance on torches, wire feed liners, contact tips, and gas shielding setups (e.g., purge bags/enclosures) to protect weld cleanliness.
• Cross-Functional Rework & Quality: Work with quality and non-conformance review (NCR) teams to disposition weld indications, evaluate NDT results, and execute precision TIG rework/cutback strategies when required.

Required Qualifications

• Education: B.S. or M.S. in Welding Engineering, Materials Science/Metallurgy, Mechanical Engineering, or a related field.
• Experience: 3+ years of hands-on experience in automated arc welding (GTAW/TIG, PAW, GMAW) or Wire directed energy deposition (WAAM / DED).
• Weld Inspection Expertise: Deep knowledge of weld bead morphology, defect identification (porosity, lack of fusion, cracking, oxidation), and live optical/camera-based process diagnostics.
• Metallurgy Knowledge: Strong understanding of physical metallurgy, heat-affected zones (HAZ), thermal cycling, and shielding environments for reactive/exotic metals (Titanium, Nickel alloys, Stainless Steel).
• Hands-On & Floor Focused: Direct experience working alongside shop-floor technicians and operators to troubleshoot equipment, wire feeders, torches, and process parameters.

Preferred Qualifications

• Experience with camera/optical vision systems for weld tracking, keyhole/melt pool sizing, or continuous process monitoring.
• Direct experience with Wire Arc Additive Manufacturing (WAAM) or Plasma Arc Additive Manufacturing (PAM).
• AWS Certified Welding Engineer (CWEng) or Certified Welding Inspector (CWI).
• Familiarity with aerospace quality standards (AS9100, AWS D17.1, NAVSEA/ASME equivalent).
• Background in fast-paced factory development, rapid prototyping, or startup environments.

Compensation & Benefits

• Base Salary: Depending on experience
• Equity participation
• Full benefits package (medical, dental, vision)
• Flexible PTO