Welding Engineer

Booz Allen Hamilton•Warren, MI

1d•$55,200 - $126,000

About The Position

Develop welding techniques, procedures, and applications of welding experiments to resolve metal fabrication challenges. Conduct research and development to test fabrication processes, improve or develop welding equipment, and evaluate emerging technologies, including metallic additive manufacturing and solid-state processes. Validate mechanical testing and metallurgical assessments, and interpret Non-Destructive Testing (NDT) results. Participate in and monitor testing, modeling, and simulation efforts; develop test plans; and analyze results to determine system performance and recommend corrective actions. Establish welding procedures addressing specification restrictions, advanced material processing, and pre- and post-heating requirements for complex alloys and critical joints. Ensure compliance with established welding procedures and standards, and oversee weld testing for conformance with national and military code requirements. Lead and coordinate multidisciplinary project teams conducting advanced welding, materials joining, and research and development activities. Develop technical reports based on research and development efforts and failure-analysis investigations, and oversee schedules and milestones to ensure engineering solutions and deliverables align with mission objectives.

Requirements

5+ years of experience as a welding engineer.
Experience troubleshooting, diagnosing, and resolving complex welding production bottlenecks, defect root causes, and challenges as a technical lead.
Experience with Computer Aided Engineering (CAE) tools and Finite Element Analysis (FEA) to model weld distortion, residual stresses, and thermal cycling to optimize weld joint design.
Experience implementing weld joint optimizations, process efficiency improvements, and material rationalization.
Experience researching, developing, and implementing joining technologies, including metallic additive manufacturing, solid-state joining, and programming automated or robotic welding systems for heavy structures.
Experience interpreting and applying American Welding Society (AWS) structural codes to heavy manufacturing.
Knowledge of welding processes and industry applications.
Ability to obtain a Secret clearance.
Bachelor’s degree in Welding Engineering, Materials Engineering, or Mechanical Engineering.

Nice To Haves

Knowledge of the physical and mechanical metallurgy of complex materials used in ground vehicles.
Knowledge of military combat and tactical vehicle welding specifications and requirements.
Knowledge of DoD quality assurance, acceptance sampling, and non-destructive evaluation acceptance as they pertain to complex welded structures.
Master’s degree in Welding Engineering or Materials Science.
AWS Certified Welding Engineer (CWEng) Certification.

Responsibilities

Develop welding techniques, procedures, and experimental applications to resolve metal fabrication challenges.
Conduct research and development to test fabrication processes, improve or develop welding equipment, and evaluate emerging technologies such as metallic additive manufacturing and solid-state processes.
Validate mechanical testing and metallurgical assessments, and interpret NDT results.
Participate in and monitor testing, modeling, and simulation efforts; develop test plans; and analyze test results to determine system performance and recommend corrective actions.
Establish welding procedures for specification restrictions, advanced material processing, and pre- and post-heating requirements for complex alloys and critical joints.
Ensure compliance with welding procedures and standards, and oversee weld testing for conformance with national and military code requirements.
Lead and coordinate multidisciplinary teams working on advanced welding, materials joining, and research and development activities.
Develop technical reports based on research and development efforts and failure-analysis investigations.
Oversee schedules and milestones to align engineering solutions and deliverables with mission objectives.