Welding Engineer

Job Description: Certified Welding Engineer – Engine Manifold FabricationJob SummaryThe 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 ResponsibilitiesDevelop, 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 QualificationsBachelor’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 metallurgyWeld joint design and weld symbolsWPS/PQR and welder qualificationHeat input and distortion managementWeld defects and failure mechanismsGD&T and engineering drawingsFabrication tooling and fixturesRoot Cause Analysis (RCA)NDT/NDE techniquesAbility to work directly with production welders, fabrication suppliers, quality personnel, and design engineers.Certification / Preferred QualificationsAWS 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 ExperienceThe ideal candidate should have experience with:Large diesel-engine manifold fabricationComplex welded sheet-metal/tubular assembliesFlange-to-pipe/manifold weldingHigh-temperature componentsControlling flange flatness and dimensional distortion after weldingWeld fixture design and improvementPrototype-to-production manufacturing developmentSupplier welding/process auditsFailure analysis and weld-quality improvementReducing weld rework, scrap, leakage, and dimensional nonconformance