Welding and Joining Engineer, Body in White

Summary

The BIW Welding & Joining Engineer ensures optimal joining conditions throughout all Body-in-White (BIW) processes, maintaining structural integrity across SPR, welding, adhesive bonding, and other joining methods. This role drives robust process design, seamless handover from Manufacturing Engineering to Operations, and continuous improvement of joining technologies and assembly systems. The ideal candidate brings strong expertise in welding processes, metallurgy, and automation technologies, with a focus on quality, efficiency, and structural durability.

You Will

• Design, develop, and validate welding and joining processes (spot welding, MIG/MAG, laser welding, clinching, adhesive bonding, riveting, etc.).

• Define welding parameters, schedules, and process limits for various materials including mild steel, high-strength steel, and aluminum.

• Optimize weld sequencing and layouts to reduce distortion and improve structural performance.

• Collaborate with tooling and equipment suppliers for welding cell and automation line integration.

• Support commissioning of welding equipment including robots, weld guns, and controllers.

• Oversee try-outs, prove-outs, and validation of new welding systems.

• Ensure all welding processes meet quality, durability, and regulatory standards.

• Conduct weld inspections using NDT methods such as ultrasonic, X-ray, and destructive testing.

• Establish and maintain weld quality standards and visual inspection criteria.

• Monitor welding processes via SPC and data acquisition systems to ensure stability.

• Lead root cause analysis and corrective actions for weld defects (e.g., spatter, porosity, burn-through).

• Implement process improvements to enhance robustness, reduce cycle time, and lower cost.

• Prepare and maintain weld process documentation including WPS, PQRs, and work instructions.

• Ensure compliance with AWS, customer-specific, and other relevant industry standards.

• Collaborate closely with design, simulation, materials, and production teams on weldability and manufacturability.

• Participate in DFM reviews, PFMEA activities, and product development discussions.

• Provide regular updates to plant leadership and global Manufacturing Engineering.

You Bring

• Strong knowledge of welding and joining methods (resistance spot welding, arc welding, lasers, adhesives, rivets, etc.).

• Hands-on experience with welding automation systems and industrial robots.

• Proficiency with weld programming and control systems (e.g., Bosch, WTC, Fronius).

• Solid understanding of materials behavior, metallurgy, and heat-affected zones.

• Strong analytical and problem-solving skills, including RCA methodologies.

• Experience with Fanuc, Kawasaki, ABB, or Kuka robotic applications.

• Bachelor’s degree in Mechanical, Welding, Materials, or Manufacturing Engineering (or related field).

• 5+ years of welding/joining engineering experience in an automotive Body in White environment.

• Certified Welding Engineer (CWE) or equivalent preferred.

• Experience launching new vehicle programs within an OEM or Tier 1 environment.