Welding Engineer: Houston, TX

We are seeking an experienced Welding Engineer / Process Specialist focused on Resistance Seam Welding (RSEW) to support our precision bellows and flexible metal conduit manufacturing operations. This role is responsible for process development, schedule qualification/optimization, training, and technical compliance in accordance with AWS D17.2 and Nadcap (AC7110/4) requirements.

• Process Development & Parameter Optimization: Develop, qualify, and optimize Resistance Seam Welding (RSEW) schedules for thin-gauge nickel alloys (Inconel 625/718, Hastelloy), stainless steels (300-series, 321, 316L), and titanium used in flexible bellows assemblies.
• Specification Compliance (AWS D17.2): Establish, document, and maintain Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) in strict alignment with AWS D17.2 Class A, B, and C requirements.
• Nadcap Accreditation: Serve as the technical lead for Nadcap welding audits (AC7110 and AC7110/4 for Resistance Welding). Manage compliance matrices, pre-audit gap analyses, and prompt corrective actions (Root Cause & Corrective Action / RCCA).
• Tooling & Fixturing Design: Collaborate with tooling and design teams to engineer precision electrode wheels, chill rings, expanding mandrels, and alignment fixtures to ensure repeatable setup, consistent weld quality, and minimal heat-affected zone (HAZ) distortion.
• Metallurgical & Mechanical Testing: Coordinate metallographic preparation and evaluate metallographic cross-sections, micro-hardness profiles, peel/shear tests, and pressure/burst tests to verify joint integrity and weld nugget overlap per drawing and specification requirements.
• Shop Floor Support & Operator Qualification: Lead training, technical oversight, and formal performance qualification of resistance welding operators in accordance with aerospace standards.
• Continuous Improvement: Troubleshoot weld defects (e.g., expulsion, cracking, porosity, incomplete fusion) using root-cause analysis methodologies, 5-Why, and Statistical Process Control (SPC).

Education & Experience:

• Bachelor’s Degree in Welding Engineering, Materials Science, Metallurgy, or Mechanical Engineering with 2+ years of hands-on resistance welding experience; OR
• Associate Degree in Welding Technology / Manufacturing Technology with 5+ years of direct experience programming, qualifying, and troubleshooting Resistance Seam Welding (RSEW) equipment in a regulated manufacturing environment.

Technical Competencies:

• Direct experience developing and qualifying welding procedures to AWS D17.2 (Specification for Resistance Welding for Aerospace Applications).
• Proven track record participating in or leading Nadcap AC7110/4 (Resistance Welding) audits and compliance tasks.
• In-depth understanding of resistance welding controllers (e.g., weld monitors, constant current/energy feedback, secondary monitoring systems) and machine calibration procedures.
• Familiarity with thin-walled tubular components, expansion joints, or hydroformed/edge-welded bellows geometries is highly preferred.
• Strong background in blueprint reading, GD&T, and AS9100 quality management system requirements.
• Certified Welding Engineer (CWEng) or ASQ certification is an asset.

• Split between office engineering workstations, metallurgical testing labs, and active shop floor environments.
• Ability to inspect precision weld samples under magnification and review macro/micrographs.
• Must be a U.S. Citizen or Permanent Resident (Green Card holder) due to export compliance (ITAR/EAR) requirements.

• Houston, Texas
• 100% On-site

Full-time, Exempt