Welding Engineer

Description

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.