Technical Expert - HV Battery Welding

Ford-Motor-Company; Allen Park (MI); Hybrid; USD 116,000 - 218,000; Full time

Benefits offered by this job

Medical and dental coverage

Vehicle discount program

Tuition assistance

Flexible family care days

Job summary

Ford Motor Company seeks a senior welding engineer for electrified powertrain programs in Michigan. The role leads HV battery welding design, develops requirements, and drives testing and process control across global teams.

The candidate should have 5+ years in laser/ultrasonic welding in automotive, strong mechanics of materials, and experience with DFMEA and Six Sigma methodologies.

Qualifications

• BS minimum with MS preferred in Welding, Electrical, or Mechanical Engineering.
• 5+ years laser and ultrasonic welding in automotive or similar field experience.
• Strong mechanics of materials background.
• Expertise in battery welding processes and joint design.
• Experience with welding process control, SPC, and QC methods.
• Foundation documents such as DFMEA, P Diagram, B Diagram knowledge.
• Six Sigma Black Belt certification or progress toward.

Responsibilities

• Lead welding design and process development for HV battery systems.
• Develop and update welding requirements, test methods, and design rules.
• Provide technical leadership to resolve field welding issues.
• Develop and disseminate welding strategies and tools.
• Collaborate with global teams to improve processes and data analysis.
• Create training material and educate engineers on welding topics.
• Support ESOWs/RFIs/RFQs and supplier visits/reviews.
• Ensure interfaces between structural, propulsion, and battery teams.

Skills

Laser welding

Ultrasonic welding

Welding processes fundamentals

Mechanical engineering background

Battery welding knowledge

Six Sigma Black Belt

Education

BS in Welding, Electrical, or Mechanical Engineering

MS preferred

Tools

DFMEA

P Diagram

Job description

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

In this position... The batteries in the electrified propulsion system rely heavily on their structural system to maintain battery cell integrity for performance and durability. This requires a challenging structural design with unique hardware to deliver. Current industry solutions involve using welding techniques to join materials to improve robustness, manufacturing cycle time, and optimal package space. Laser welding is becoming one of the most common welding techniques seen in HV Battery manufacturing. The structural and welding design and requirements must be developed with a focus on function and failure mode avoidance including material selection, joint design, process capability, and process failure modes. Deep technical understanding is necessary regarding the welding processes (laser, TIG, MIG, Ultrasonic), weld joint design, material compatibility, welding process design/control, design for manufacturing, and testing.

1. For Electrified Powertrain Engineering Relased structural, cell tab, cell to bus bar, voltage sense lead, and internal cell welding :

• a) Lead the technical assessment sign-off of HV battery internal welding performance via deep dive reviews, fit and function reviews, checklist evidence, deviation requests and milestone sign-off.
• b) Lead the development of new and update requirements, design rules, DVP, and test methods associated with welding and drive the transition from Engineering Specifications to corporate standard engineering documents in FEDE.
• c) Lead development and maintenance of welding failure mode avoidance foundation documents.
• d) Provide technical leadership to field resolution
• e) Lead the development, formalization and dissemination of welding strategies, processes, and issue resolution tool sets.
• f) Lead the development of new technologies, methods, and material applications, engaging non-Electrified Propulsion Engineering organizations as needed to deliver the best welding solutions that maximize value for the company.
• g) Develop and improve the interfaces the structural community and associated engineering process in the vibration and crash attributes
• h) Support the evolution from physical evaluations toward analytical evaluations of welding systems.

2. Support the creation of ESOWs and RFIs/RFQs and supplier visits/reviews.

3. Be a single global point of contact for welding delivery internally and with full-service suppliers.

4. Lead the development of training material and the education of Ford engineers in relation to welding topics.

5. Support competitive benchmarking and research activities.

6. Collaborate globally with the Ford technical community to foster communication, process improvements, and advancements.

You'll have...

1. BS minimum with MS preferred in Welding, Electrical, or Mechanical Engineering

2. 5+ years laser and ultrasonic welding in automotive or similar field experience

3. Strong mechanics of materials background

Even better, you may have... 4. Expertise in battery welding processes fundamentals a)Resistance welding: Spot welding, seam welding (especially for tabs, bus bars and cell connections). Understanding parameters like current, voltage, force, and pulse time. b)Laser Welding: Pulsed laser welding, continuous laser welding. Understanding power speed, focus, and shielding gas c)Ultrasonic welding: Understanding amplitude, force, and time d)Ability to select appropriate welding methods and parameters based on material type, thickness, and joint design.

5. Expertise in welded joint design for various functions and failure mode avoidance

a)Understanding of spatter free zones

b)Understanding of CQI-15 and 2D drawing requirements for welds

c)Knowledge of electrical principles related to battery connections and resistance to support efficient and robust design

d)Awareness of relevant industry standards (e.g., safety standards, quality standards like ISO 9001, or specific automotive/aerospace standards if applicable).

e)Strong mechanics of materials background and welding metallurgy

6. Expertise in welding process control methods and associated metrics

a)Knowledge of Statistical Process Control (SPC) principles an Key Process Input Variables of welding process.

b)Experience with vision systems or other inspection technologies integrated into welding processes

c)Understanding of fixturing requirements for precise and repeatable welding

d)Experience with process set-up, optimization, and validation.

7. Expertise in Welding Quality control methods

a)Experience with destructive testing methods like pull/shear testing and understanding results.

b)Experience with non-destructive testing methods (like resistance testing and X-ray inspection and cross section analysis) to demonstrate quality

8. Foundation

a)Strong experience in developing foundation documents (DFMEA, P Diagram, B Diagram, SCCAF, etc.)

b)Experience in development of requirements, design rules, and test methods

c)Six Sigma Black Belt certified (or in process of becoming certified)

9. Experience in helping resolve field issues associated with the welding

10. Knowledge of welding in designs from our competition

11. Fundamental understanding of battery cell types (e.g., cylindrical, pouch, prismatic), basic pack construction, and the purpose of cell interconnects and busbars.

12. Understanding of battery safety protocols, particularly regarding handling, potential short circuits, and thermal events during assembly.

13. General Skills

a) Experience working with D&R engineering, CAE analysis, and testing teams across multiple organizations

b) Working knowledge of the GPDS milestones and timing, their deliverables, and evidence required as it relates to welding design and process development

c)Strong data analysis skills

d) Excellent communication, teaching, presentation, and analytical skills.

e) Broad interpersonal skills, enabling team facilitation and effective interfacing with cross-functional teams

f) Candidates must be able to work under operational pressures and to set priorities for themselves and for team members

g) Strong working relationships with global counterparts in Battery Manufacturing Engineering, STA, structures, and industry desired

h) Experience developing and evaluating new concepts and design ideas desired

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is leadership level 6 and ranges from $115,500-$218,100. Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week. #LI-Hybrid #LI-KH2