Jobs via Dice ยท 1 day ago
Welding and Joining Engineer
Rochester, NY
Full-time
Onsite
Senior Level, Lead/Staff
$134K/yr - $171K/yr
10+ years expToyota Material Handling North America is seeking an experienced Welding Engineer / Joining Engineer to play a key role in advancing electrified powertrains and next-generation energy storage systems for material handling equipment. In this hands-on role, you'll develop and industrialize cutting-edge joining processes and collaborate with various teams to ensure safe and reliable solutions for energy systems.
Computer Software
Responsibilities
Welding, Joining Technology & Metallurgical Engineering
Develop and optimize joining processes, including laser welding, brazing, and bonding, for energy storage applications
Lead metallurgy-driven process development for Aluminum, Copper and high-strength steels
Perform metallurgical evaluations, including microstructure analysis, Heat-Affected Zone characterization, hardness testing, and weld sectioning
Conduct weld trials, define process windows, evaluate joint quality, and ensure long-term reliability based on material behavior
Partner with equipment suppliers to specify welding systems, tooling, jigs, fixtures, and automation
Support the development of joining processes used in battery pack enclosures, busbars, cooling plates, and electro-mechanical interfaces
Drive the lock-step introduction of NDE techniques alongside new joining processes, ensuring inspection strategies are fully embedded before manufacturing scale-up
Develop NDE solutions such as X-ray/radiography, vision inspection, and weld-quality monitoring tools
Validate NDE methods for repeatability, capability, and suitability for both prototype and high-volume manufacturing
Implement NDE techniques that prevent scrap and reduce dependence on destructive testing
Industrialize joining and inspection processes into manufacturing using structured process validation, tool qualification, PFMEA/DFMEA, SPC, and DOE
Support prototype builds and transition joining processes to pilot lines and production environments
Troubleshoot process issues involving weld quality, materials behavior, design interactions, or equipment variation
Conduct capability studies, GR&R, weld parameter optimization, and statistical analysis to ensure process robustness
Lead structured failure analysis for weld-related or materials-related issues, including fractography, fatigue, cracking, and corrosion mechanisms
Document findings in clear technical reports and communicate results to engineering, quality, and manufacturing partners
Collaborate with Mechanical Engineering, Electrical Engineering, BMS, Manufacturing, Validation, and suppliers to ensure fully integrated joining solutions
Maintain awareness of new welding, joining, and NDE technologies, introducing innovations that strengthen TMHNA's competitiveness
Support both laboratory and production environments to execute trials, inspections, and troubleshooting
Qualification
Required
B.S. in Welding Engineering, Mechanical Engineering, Materials Science, or related discipline
10+ years of welding engineering, welding research, or NDE experience
Experience welding Copper, Aluminum, or high-strength steels
Experience with NDE techniques, including X-ray or ultrasonic inspection
Demonstrated capability in data analysis, documentation, and experimental interpretation
Strong communication, teamwork, and interpersonal skills
Self-starter capable of managing complex, multi-disciplinary assignments
Passion for innovation and continuous improvement
Preferred
Master's degree in Materials Science, Welding Engineering, Mechanical Engineering, or related field
5+ years of advanced experience with NDE methods and complex joining technologies
Experience with advanced development work including literature reviews, gap analysis, experimental planning, and technical reporting
Background in automotive manufacturing, electrified powertrains, or battery systems
Hands-on expertise in mechanical testing, metallography, and sample preparation
Proficiency with statistical and data analysis tools (Minitab, JMP, Python, R)
Laboratory and/or plant experience supporting manufacturing process development or troubleshooting
Familiarity with UL, IEC, EN, ANSI, AS9100, J-STD-001, and GD&T (ASME Y14.5)
Deep understanding of welding metallurgy, material transformations, and joint behavior
Proven ability to scale advanced joining technologies into production environments
Strong analytical mindset grounded in materials science and failure analysis
Benefits
Competitive Salary
Performance Bonus
Generous Paid Time Off and 13 Paid Holidays
Affordable Medical plans and no-cost Dental & Vision options
100% 401(k) match up to 6%
Company-Paid Life Insurance, Short-Term Disability, and Long-Term Disability
Tuition Assistance Program
Employee Assistance Program (EAP) with access to mental health care, legal support, and financial guidance
Recognition and Kaizen (continuous improvement) Reward Programs
Meaningful opportunities for personal and professional development
Best in class work culture!
Company
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