Joining Engineer
Confirmed on the employer's own hiring board on Oct 24, 2026. First seen by Alion on Oct 22, 2026. SEGULA Technologies scores A on the Alion truth index.
About the Role
We are seeking an experienced Joining Engineer specializing in Cold Metal Transfer (CMT) welding and advanced joinery for high-volume automotive manufacturing. In this role, you will lead process development, parameter optimization, and continuous improvement across automated Body-in-White (BIW) and battery structure production lines.
You will focus on joining challenging materials-such as thin-gauge aluminum, ultra-high-strength steels (UHSS), and hybrid assemblies-while ensuring high line efficiency, minimal spatter, and strict safety-critical weld quality.
Key Responsibilities
CMT Process Optimization: Develop, qualify, and stabilize Fronius CMT welding parameters across automated BIW, chassis, or battery tray production lines.
Robotic Cell Commissioning: Fine-tune automated welding cells with multi-axis robots (KUKA, ABB, FANUC) for high-speed, repeatable automotive assembly.
Defect Reduction & Line Support: Perform root-cause failure analysis (porosity, burn-through, gap variation) and implement immediate counter-measures during pre-series and ramp-up phases.
Design for Manufacture (DFM): Work with BIW design teams to optimize automotive joint configurations, gap tolerances, and fixture design for optimal heat input control.
Quality & Standards Compliance: Ensure all joints comply with automotive OEM standards, creating Welding Procedure Specifications (WPS), PQR, and executing PFMEAs.
Multi-Joining Technologies: Support secondary BIW joining techniques where applied, such as Self-Piercing Riveting (SPR), Resistance Spot Welding (RSW), and structural adhesives.