Metallurgy Process Engineer Jobs in Wisconsin (NOW HIRING)

POSITION SUMMARY:

The Welding Process Engineer is a forward-thinking position, driving continuous improvement and technological advancement in our aluminum and steel shipbuilding operations. This role focuses on enhancing welding process capability and capacity, implementing automation, and optimizing production efficiency. The Welding Process Engineer will work closely with our Certified Welding Inspector (CWI), who leads WPS, PQR, and inspection activities, to ensure alignment between process development and quality assurance.

ESSENTIAL JOB FUNCTIONS:

Analyze and improve welding process capability and throughput across aluminum, steel, stainless steel, and copper-nickel fabrication and welding areas.

Identify and implement opportunities for automation, robotics, and advanced welding technologies to increase efficiency and consistency.

Apply deep knowledge of welding metallurgy and materials science to understand and optimize weld behavior in both the weld metal and heat-affected zones of base materials.

Design and manage welding sequences to align with production stages and different vessel types. Coordinate across teams to ensure sequences meet structural and scheduling needs.

Document sequences visually for clarity and accessibility on the production floor.

Investigate and manage the interactions between welding gases, filler materials, and base metals to enhance weld quality, reduce defects, and improve vessel reliability and production efficiency.

Collaborate with the Certified Welding Inspector to ensure process improvements align with ABS and AWS standards and inspection requirements.

Lead root cause analysis and corrective actions for process-related welding issues, focusing on systemic improvements.

Collaborate with Quality and other Department staff to develop and maintain process documentation, including standard work instructions and process control plans.

Evaluate new equipment, tools, and materials to support innovation in welding and fabrication.

Support lean manufacturing initiatives and continuous improvement projects across the production floor.

Monitor and report on key performance indicators (KPIs) related to welding productivity, quality, and cost.

Develop and qualify Welding Procedure Specifications (WPS) in accordance with applicable codes and standards to ensure consistent weld quality and compliance.

Provide training and technical support to welders, promoting best practices, proper techniques, and the adoption of new welding technologies.

Oversee weld inspections and coordinate nondestructive testing (NDT) activities to verify weld integrity and ensure compliance with quality standards.

Analyze welding-related costs and contribute to budgeting efforts, identifying opportunities for cost reduction and process efficiency.

Lead cross-functional engineering projects, including Design for Manufacturability (DFM) initiatives and new product introductions, to optimize welding processes.

Ensure compliance with environmental, health, and safety (EHS) regulations, maintaining a safe and compliant welding environment.

Implement and manage digital welding technologies, such as weld monitoring systems and traceability tools, to enhance process control and data-driven decision-making.

POSITION IN ORGANIZATION:

This position reports directly to the Director of Manufacturing and has no direct reports.

LEADERSHIP:

Demonstrates leadership through technical mentorship, cross-functional collaboration, and a commitment to team success. Encourages innovation, continuous learning, and a positive work environment.

DECISION MAKING:

Exercise judgment consistent with our mission, vision, and code of business conduct regularly and continuously. Makes informed decisions regarding welding processes, quality standards, and production support.

COMMUNICATION:

Shall demonstrate ability to effectively lead meetings and write professional correspondence. Great verbal and written communication skills, including the ability to listen, talk, and teach. Demonstrate an all-pervasive positive attitude.

ADDITIONAL EXPECTATIONS:

Collaborate with engineering and design teams to ensure weldability of new designs.

Support/provide training and guidance to welders on new procedures and technologies.

Participate in audits and inspections by regulatory bodies.

Support the development of capital investment plans for welding equipment and infrastructure.

QUALIFICATIONS:

Bachelor’s degree in Welding Engineering, Mechanical Engineering, Materials Science, Industrial Engineering, or a related field.

3–5 years of experience in welding process engineering, preferably in shipbuilding or heavy fabrication.

Strong understanding of ABS Part 2: Rules for Materials and Welding, AWS D1.1 (Steel), and AWS D1.2 (Aluminum).

Demonstrated expertise in welding metallurgy, including microstructure evolution, heat-affected zones, and mechanical properties of welded joints.

Experience with welding automation, robotics, and advanced manufacturing technologies.

Familiarity with lean manufacturing, Six Sigma, or similar continuous improvement methodologies.

Excellent analytical, communication, and project management skills.

Proficiency in CAD and process simulation tools is a plus.

PHYSICAL REQUIREMENTS:

This job operates in a shipyard manufacturing environment. This role must routinely use the personal protective equipment, tools, machinery, and products used in the welding department. The position also requires regular visits to the production floor, which requires climbing stairs and inspecting items in tight spaces.

Exposure to weld gases, arches, sparks, flashes, paints, chemicals, fumes, airborne particles, moving mechanical parts, and other production operations is likely.