Welding Engineer

Summary:

The Welding Engineer is responsible for developing, qualifying, and continuously improving welding processes for spiral-welded wind tower manufacturing. This role ensures strict compliance with AWS D1.1, ISO 9001, and specific customer requirements (e.g., GE), serving as a critical link between engineering and operations to drive high-quality, efficient welds across production.

Key Responsibilities:

- Develop, document, and maintain WPS, PQR, and WPQR for SAW, GMAW, FCAW, GTAW, and automated welding processes.

- Lead welding trials and parameter optimization using Lincoln Power Wave AC/DC 1000 and related equipment; analyze waveform and process data to enhance arc stability, heat input control, and deposition efficiency.

- Diagnose and resolve welding issues (e.g., porosity, incomplete fusion, arc-strike inconsistencies) using root cause analysis tools such as 8D and 5-Why.

- Partner with Manufacturing Engineering to develop fixtures, manipulators, and robotic welding cells, supporting new product introductions and mobile manufacturing ("in-field factory") concepts.

- Collaborate with Quality to disposition NCRs, validate repair procedures, and ensure inspection/test plans align with AWS D1.1 and customer specifications.

- Train, qualify, and support welders; maintain welder continuity records and conduct performance testing.

- Provide welding expertise during product design reviews, including input on joint configurations, weld symbols, and manufacturability.

- Lead continuous improvement initiatives to improve throughput, reduce cost, and increase first-pass yield using Lean and Six Sigma methodologies.

- Maintain welding consumable specifications and support Supply Chain with vendor qualification and performance monitoring.

- Stay current on welding standards, technologies, and industry trends; recommend process and equipment upgrades as needed.

Required Qualifications:

- Bachelor’s degree in Welding Engineering, Materials Science, Mechanical Engineering, or a related discipline.

- Minimum 5 years of experience in heavy steel fabrication, preferably involving SAW and large-diameter pipe or tower welding.

- Strong working knowledge of AWS D1.1 and experience preparing and qualifying welding procedures.

- Proficiency with advanced welding equipment and waveform control systems (e.g., Lincoln Power Wave); ability to interpret waveform data and logs.

- Proven ability to troubleshoot and optimize automated welding processes.

- Familiarity with ISO 9001 quality management systems and APQP methodologies.

- Competence in CAD (SolidWorks or Inventor) and interpreting complex fabrication drawings.

Preferred Qualifications:

- AWS CWI, CWE, or SCWI certification.

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

- Exposure to advanced inspection systems (e.g., photogrammetry) and statistical process control.

- Lean Six Sigma Green Belt certification.

- Experience with ERP and PLM systems (e.g., Omega, Intelex, SAP).

Soft Skills:

- Strong shop-floor presence with a hands-on approach and ability to lead through influence.

- Excellent analytical, communication, and technical documentation skills.

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

Physical Requirements:

- Ability to stand, walk, climb ladders, and lift up to 50 lbs in a production setting.

Travel:

Up to 15%, including vendor visits and travel to in-field factory sites.

Work Authorization:

Must be authorized to work in the United States.