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

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

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

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

The ideal candidate should have experience with:

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