Weld Engineer

GABLETEK; Warsaw (IN); On-site; USD 70,000 - 100,000; Full time

Job summary

GABLETEK in Warsaw, IN seeks a hands-on Weld Engineer to support automated welding operations on the shop floor. You will understand why welds perform as they do and implement adjustments to ensure production-quality results.

The role involves evaluating weld quality, performing coupon testing and cut-etch analyses, diagnosing defects, and collaborating with robot programmers and manufacturing engineers to drive continuous improvement on welded assemblies.

Qualifications

• Hands-on welding engineering and automated/robotic welding background.
• Experience with GMAW/MIG welding processes and weld testing.
• Ability to evaluate weld coupons and cut-etch tests.
• Troubleshoot weld quality issues and adjust processes.

Responsibilities

• Evaluate automated weld quality against specifications.
• Perform weld coupon samples to verify penetration, fusion, size, and integrity.
• Conduct cut- and-etch testing to evaluate penetration and fusion.
• Identify good vs bad weld characteristics and root causes.
• Adjust welding parameters and material handling to improve quality.
• Collaborate with robot programmers, controls engineers, and production teams.
• Document weld settings, test results, and corrective actions.
• Support weld process development and continuous improvement.

Skills

Welding engineering

Automated/robotic welding

GMAW/MIG processes

Coupon & cut-etch testing

Weld parameter troubleshooting

On-site manufacturing floor experience

Job description

Weld Engineer – Direct Hire

Location: Warsaw, Indiana
Employment Type: Direct Hire / Full-Time
Industry: Industrial Automation / Manufacturing

Position Overview

We are seeking a hands‑on Weld Engineer to support automated welding operations in Warsaw, Indiana. This position requires someone who understands the complete welding process—not just how to identify a good or bad weld, but why the weld is performing the way it is and what adjustments are needed to correct it.

The ideal candidate will be comfortable working directly on the manufacturing floor, evaluating weld quality, performing coupon testing, cut‑and‑etch analysis, troubleshooting weld defects, and making process changes to achieve consistent, production‑quality welds.

Key Responsibilities

• Evaluate automated weld quality and determine whether welds meet required specifications and quality standards.
• Perform and evaluate weld coupon samples to verify weld penetration, fusion, size, profile, and overall integrity.
• Perform cut‑and‑etch / macro‑etch testing of weld samples to evaluate penetration and fusion.
• Identify good vs. bad weld characteristics and clearly determine the cause of unacceptable welds.
• Diagnose common weld defects, including:
  • Lack of penetration
  • Lack of fusion
  • Porosity
  • Undercut
  • Burn‑through
  • Excessive or insufficient weld size
  • Spatter
  • Poor bead profile
  • Inconsistent weld appearance
• Make appropriate adjustments to welding parameters based on coupon and cut/etch results.
• Understand the relationship between welding variables and final weld quality.
• Adjust parameters such as:
  • Voltage
  • Amperage / wire feed speed
  • Travel speed
  • Torch angle and position
  • Contact‑tip‑to‑work distance
  • Gas flow
  • Weld sequence
  • Robot speed and weld path
• Understand what happens when individual weld parameters are changed and how those changes affect penetration, heat input, bead profile, spatter, fusion, and overall weld quality.
• Troubleshoot weld issues and determine whether the root cause is related to weld parameters, tooling/part fit‑up, material condition, consumables, equipment, or robot positioning.
• Work closely with robot programmers, controls engineers, manufacturing engineers, quality personnel, and production teams to optimize welding processes.
• Support weld process development, validation, troubleshooting, and continuous improvement.
• Document weld settings, test results, process changes, and corrective actions.
• Assist with establishing and maintaining repeatable welding processes for production.

Qualifications

• Strong hands‑on background in welding engineering, weld process development, or automated/robotic welding.
• Strong understanding of GMAW/MIG welding processes.
• Experience performing and interpreting weld coupon and cut‑and‑etch testing.
• Ability to visually inspect welds and recognize acceptable and unacceptable weld conditions.
• Strong understanding of cause and effect when changing welding parameters.
• Ability to troubleshoot weld quality issues and make effective process adjustments.
• Experience supporting robotic welding systems strongly preferred.Automotive, structural, fabrication, or high‑volume automated manufacturing experience preferred.
• Strong problem‑solving skills and willingness to work hands‑on with production equipment.

Ideal Candidate

The ideal candidate is someone who can look at a weld or cut‑and‑etched coupon, identify what is wrong with it, explain why it happened, and know exactly what process changes should be made to correct it. This is a hands‑on position for someone who understands the science behind welding while also being comfortable making practical adjustments on the manufacturing floor.