Welding Engineer

Job Description: Certified Welding Engineer – Engine Manifold Fabrication

Job Summary

The Certified Welding Engineer will provide technical leadership for the fabrication, welding, inspection, and quality improvement of engine exhaust/intake manifolds and related welded assemblies . The engineer will be responsible for developing and qualifying welding processes, resolving fabrication and weld-quality issues, and ensuring welded components meet engineering drawings, specifications, dimensional requirements, and applicable welding standards.

The position requires strong hands-on knowledge of sheet-metal fabrication, weld joints, fixtures, distortion control, metallurgy, inspection, and root-cause analysis

Key Responsibilities

• Develop, review, and optimize welding and fabrication processes for engine manifolds, risers, crossover pipes, brackets, flanges, and associated welded assemblies
• Develop and maintain Welding Procedure Specifications (WPS) and support Procedure Qualification Records (PQR) and welder performance qualification activities.
• Define appropriate welding processes, joint designs, weld sizes, sequences, parameters, filler materials, and acceptance criteria
• Review engineering drawings, 3D models, GD&T, material specifications, weld symbols, and manufacturing requirements for manufacturability.
• Support fabrication of sheet-metal and tubular components, including forming, cutting, fit-up, tack welding, fixturing, welding, and final inspection
• Develop welding fixtures and recommend clamping/welding sequences to minimize distortion, warpage, dimensional variation, and assembly mismatch
• Establish appropriate inspection and verification methods for welded assemblies, including visual inspection and applicable NDT/NDE techniques.
• Investigate weld-related defects such as cracking, porosity, lack of fusion, incomplete penetration, undercut, dimensional distortion, and recurring rework.
• Lead root-cause analysis and corrective actions for manufacturing and field-quality problems.
• Work with Design Engineering to improve weld accessibility, joint configuration, tolerances, material selection, and Design for Manufacturability (DFM)
• Support prototype builds, production launch, supplier development, and ongoing Continuous Product Improvement activities.
• Work directly with fabrication suppliers to review welding capability, process controls, quality performance, and corrective actions.
• Maintain welding process documentation, work instructions, inspection requirements, process control plans, and manufacturing records.
• Provide technical guidance and training to welders, technicians, manufacturing engineers, inspectors, and suppliers.

Required Qualifications

• Bachelor's degree in Welding Engineering, Mechanical Engineering, Manufacturing Engineering, Materials/Metallurgical Engineering , or a closely related engineering discipline.
• Strong professional experience in welding engineering and fabricated metal assemblies
• Practical knowledge of MIG/GMAW, TIG/GTAW and other welding processes applicable to manifold fabrication.
• Experience with carbon steel, stainless steel, alloy steel, and/or high-temperature materials used in engine-related applications.
• Strong understanding of:
• Welding metallurgy
• Weld joint design and weld symbols
• WPS/PQR and welder qualification
• Heat input and distortion management
• Weld defects and failure mechanisms
• GD&T and engineering drawings
• Fabrication tooling and fixtures
• Root Cause Analysis (RCA)
• NDT/NDE techniques
• Ability to work directly with production welders, fabrication suppliers, quality personnel, and design engineers.

Certification / Preferred Qualifications

• AWS Certified Welding Engineer (CWEng) or comparable recognized welding-engineering qualification preferred.
• AWS Certified Welding Inspector (CWI) would be an advantage where the position includes significant weld inspection responsibility.
• Working knowledge of applicable AWS, ASME, ISO, or customer-specific welding standards , depending on the manifold design and governing specification.
• CAD experience with Creo, CATIA, NX, SolidWorks, or equivalent preferred.
• Experience in diesel engines, heavy equipment, automotive, off-highway, power generation, or exhaust-system fabrication is strongly preferred.

Preferred Engine-Manifold Experience

The ideal candidate should have experience with:

• Large diesel-engine manifold fabrication
• Complex welded sheet-metal/tubular assemblies
• Flange-to-pipe/manifold welding
• High-temperature components
• Controlling flange flatness and dimensional distortion after welding
• Weld fixture design and improvement
• Prototype-to-production manufacturing development
• Supplier welding/process audits
• Failure analysis and weld-quality improvement
• Reducing weld rework, scrap, leakage, and dimensional nonconformance