Technical Expert - HV Battery Welding

Ford Motor • Allen Park, MI

2d • Hybrid

About The Position

The batteries in the electrified propulsion system rely heavily on their structural system to maintain battery cell integrity for performance and durability. This requires a challenging structural design with unique hardware to deliver. Current industry solutions involve using welding techniques to join materials to improve robustness, manufacturing cycle time, and optimal package space. Laser welding is becoming one of the most common welding techniques seen in HV Battery manufacturing. The structural and welding design and requirements must be developed with a focus on function and failure mode avoidance including material selection, joint design, process capability, and process failure modes. Deep technical understanding is necessary regarding the welding processes (laser, TIG, MIG, Ultrasonic), weld joint design, material compatibility, welding process design/control, design for manufacturing, and testing.

Requirements

• BS minimum with MS preferred in Welding, Electrical, or Mechanical Engineering
• 5+ years laser and ultrasonic welding in automotive or similar field experience
• Strong mechanics of materials background

Nice To Haves

• Expertise in battery welding processes fundamentals
• Resistance welding: Spot welding, seam welding (especially for tabs, bus bars and cell connections). Understanding parameters like current, voltage, force, and pulse time.
• Laser Welding: Pulsed laser welding, continuous laser welding. Understanding power speed, focus, and shielding gas.
• Ultrasonic welding: Understanding amplitude, force, and time.
• Ability to select appropriate welding methods and parameters based on material type, thickness, and joint design.
• Expertise in welded joint design for various functions and failure mode avoidance
• Understanding of spatter free zones
• Understanding of CQI-15 and 2D drawing requirements for welds
• Knowledge of electrical principles related to battery connections and resistance to support efficient and robust design
• Awareness of relevant industry standards (e.g., safety standards, quality standards like ISO 9001, or specific automotive/aerospace standards if applicable).
• Strong mechanics of materials background and welding metallurgy
• Expertise in welding process control methods and associated metrics
• Knowledge of Statistical Process Control (SPC) principles an Key Process Input Variables of welding process.
• Experience with vision systems or other inspection technologies integrated into welding processes
• Understanding of fixturing requirements for precise and repeatable welding
• Experience with process set-up, optimization, and validation.
• Expertise in Welding Quality control methods
• Experience with destructive testing methods like pull/shear testing and understanding results.
• Experience with non-destructive testing methods (like resistance testing and X-ray inspection and cross section analysis) to demonstrate quality
• Foundation
• Strong experience in developing foundation documents (DFMEA, P Diagram, B Diagram, SCCAF, etc.)
• Experience in development of requirements, design rules, and test methods
• Six Sigma Black Belt certified (or in process of becoming certified)
• Experience in helping resolve field issues associated with the welding
• Knowledge of welding in designs from our competition
• Fundamental understanding of battery cell types (e.g., cylindrical, pouch, prismatic), basic pack construction, and the purpose of cell interconnects and busbars.
• Understanding of battery safety protocols, particularly regarding handling, potential short circuits, and thermal events during assembly.
• General Skills
• Experience working with D&R engineering, CAE analysis, and testing teams across multiple organizations
• Working knowledge of the GPDS milestones and timing, their deliverables, and evidence required as it relates to welding design and process development
• Strong data analysis skills
• Excellent communication, teaching, presentation, and analytical skills.
• Broad interpersonal skills, enabling team facilitation and effective interfacing with cross-functional teams
• Candidates must be able to work under operational pressures and to set priorities for themselves and for team members
• Strong working relationships with global counterparts in Battery Manufacturing Engineering, STA, structures, and industry desired
• Experience developing and evaluating new concepts and design ideas desired

Responsibilities

• Lead the technical assessment sign-off of HV battery internal welding performance via deep dive reviews, fit and function reviews, checklist evidence, deviation requests and milestone sign-off.
• Lead the development of new and update requirements, design rules, DVP, and test methods associated with welding and drive the transition from Engineering Specifications to corporate standard engineering documents in FEDE.
• Lead development and maintenance of welding failure mode avoidance foundation documents.
• Provide technical leadership to field resolution.
• Lead the development, formalization and dissemination of welding strategies, processes, and issue resolution tool sets.
• Lead the development of new technologies, methods, and material applications, engaging non-Electrified Propulsion Engineering organizations as needed to deliver the best welding solutions that maximize value for the company.
• Develop and improve the interfaces the structural community and associated engineering process in the vibration and crash attributes.
• Support the evolution from physical evaluations toward analytical evaluations of welding systems.
• Support the creation of ESOWs and RFIs/RFQs and supplier visits/reviews.
• Be a single global point of contact for welding delivery internally and with full-service suppliers.
• Lead the development of training material and the education of Ford engineers in relation to welding topics.
• Support competitive benchmarking and research activities.
• Collaborate globally with the Ford technical community to foster communication, process improvements, and advancements.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior