Welding Engineer

Booz Allen Hamilton; Warren (MI); On-site; USD 55,000 - 126,000; Full time

Job summary

Booz Allen Hamilton in Warren, MI seeks a Welding Engineer to develop welding techniques and oversee tests for complex assemblies used in national security programs.

You will lead cross-functional teams, apply CAE/FEA to optimize welds, and align with welding standards. A Secret clearance is required.

Qualifications

• Bachelor’s degree in welding engineering, materials engineering, or mechanical engineering.
• 5+ years of welding engineer experience in heavy manufacturing.
• Experience leading troubleshooting and root-cause analysis in welding production.

Responsibilities

• Develop welding techniques, procedures, and experiments for complex alloys.
• Lead multi-disciplinary teams to deliver welding and joining solutions.
• Ensure compliance with national and military welding codes and procedures.
• Develop technical reports and test plans with schedules.

Skills

Welding engineering

Technical leadership

CAE/FEA modeling

Welding optimization

Additive manufacturing

AWS codes

Education

Bachelor’s degree in welding engineering, materials engineering, or mechanical engineering

Tools

CAE tools

FEA

Robotic welding systems

Job description

Join a culture of empowerment and connectivity.

Develop your craft

Learn the skills you need to accelerate your career.

Discover benefits that your life and work.

Innovate with intention

Build mission‑ready tech that protects the nation.

Develop welding techniques, procedures, and application of welding experiments to resolve metal fabrication challenges. Conduct research and development to test new fabrication processes, improve, or develop new welding equipment, and evaluate emerging technologies such as metallic additive manufacturing and solid‑state processes. Validate mechanical testing, metallurgical assessments, and interpret Non‑Destructive Testing (NDT) results. Participate in and monitor testing, models, and simulation efforts, develop test plans, and analyze test results to determine system performance and recommend corrective actions. Establish welding procedures to aid in specification restrictions, advanced material processing, and pre‑ and post‑heating requirements for complex alloys and critical joints. Ensure compliance with established welding procedures and standards and oversee weld testing for conformance with national and military code requirements. Lead and coordinate multi‑disciplinary project teams in the execution of advanced welding, materials joining, and research and development activities. Develop technical reports based on research and development efforts and failure analysis investigations and oversee schedules and milestones to ensure engineering solutions and deliverables align with mission objectives.

Join us. The world can't wait.

You Have:

5+ years of experience as welding engineer

Experience as a technical lead troubleshooting, diagnosing, and resolving complex welding production bottlenecks, defect root‑causes, and challenges

Experience in Computer Aided Engineering (CAE) tools and Finite Element Analysis (FEA) to model weld distortion, residual stresses, and thermal cycling to optimize weld joint design

Experience implementing weld joint optimizations, process efficiency improvements, and material rationalization

Experience with the research, development, and implementation of cutting‑edge joining technologies, including metallic additive manufacturing and solid‑state joining, and programming automated or robotic welding systems for heavy structures

Experience interpreting and applying American Welding Society (AW) structural codes to heavy manufacturing

Knowledge of welding processes and industry applications

Ability to obtain a Secret clearance

Nice If You Have:

Knowledge of the physical and mechanical metallurgy of complex materials used in ground vehicles

Knowledge of military combat and tactical vehicle welding specifications and requirements

Knowledge of DoD quality assurance, acceptance sampling, and non‑destructive evaluation acceptance as they pertain to complex welded structures

Master’s degree in welding engineering or materials science

Clearance:

Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information.

Compensation

At Booz Allen, we celebrate your contributions, provide you with opportunities and choices, and support your total well‑being. Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work‑life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full‑time and part‑time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs. Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page.

Salary at Booz Allen is determined by various factors, including but not limited to location, the individual’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract‑specific affordability and organizational requirements. The projected compensation range for this position is $55,200.00 to $126,000.00 (annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of Booz Allen’s total compensation package for employees. This posting will close within 90 days from the Posting Date.

Welding Engineer

The Opportunity:

Develop welding techniques, procedures, and application of welding experiments to resolve metal fabrication challenges. Conduct research and development to test new fabrication processes, improve, or develop new welding equipment, and evaluate emerging technologies such as metallic additive manufacturing and solid‑state processes. Validate mechanical testing, metallurgical assessments, and interpret Non‑Destructive Testing (NDT) results. Participate in and monitor testing, models, and simulation efforts, develop test plans, and analyze test results to determine system performance and recommend corrective actions. Establish welding procedures to aid in specification restrictions, advanced material processing, and pre‑ and post‑heating requirements for complex alloys and critical joints. Ensure compliance with established welding procedures and standards and oversee weld testing for conformance with national and military code requirements. Lead and coordinate multi‑disciplinary project teams in the execution of advanced welding, materials joining, and research and development activities. Develop technical reports based on research and development efforts and failure analysis investigations and oversee schedules and milestones to ensure engineering solutions and deliverables align with mission objectives.

Join us. The world can't wait.

You Have:

• 5+ years of experience as welding engineer

• Experience as a technical lead troubleshooting, diagnosing, and resolving complex welding production bottlenecks, defect root‑causes, and challenges

• Experience in Computer Aided Engineering (CAE) tools and Finite Element Analysis (FEA) to model weld distortion, residual stresses, and thermal cycling to optimize weld joint design

• Experience implementing weld joint optimizations, process efficiency improvements, and material rationalization

• Experience with the research, development, and implementation of cutting‑edge joining technologies, including metallic additive manufacturing, solid‑state joining, and programming automated or robotic welding systems for heavy structures

• Experience interpreting and applying American Welding Society (AW) structural codes to heavy manufacturing

• Knowledge of welding processes and industry applications

• Ability to obtain a Secret clearance

• Bachelor’s degree in welding engineering, materials engineering, or mechanical engineering

Nice If You Have:

• Knowledge of the physical and mechanical metallurgy of complex materials used in ground vehicles

• Knowledge of military combat and tactical vehicle welding specifications and requirements

• Knowledge of DoD quality assurance, acceptance sampling, and non‑destructive evaluation acceptance as they pertain to complex welded structures

• Master’s degree in welding engineering or materials science

• AWS Certified Welding Engineer (CWEng) Certification

Clearance:

Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information.

Compensation

At Booz Allen, we celebrate your contributions, provide you with opportunities and choices, and support your total well‑being. Our offerings include health, life, disability, financial, and retirement benefits, as well as paid leave, professional development, tuition assistance, work‑life programs, and dependent care. Our recognition awards program acknowledges employees for exceptional performance and superior demonstration of our values. Full‑time and part‑time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs. Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits. We encourage you to learn more about our total benefits by visiting the Resource page on our Careers site and reviewing Our Employee Benefits page.

Salary at Booz Allen is determined by various factors, including but not limited to location, the individual’s particular combination of education, knowledge, skills, competencies, and experience, as well as contract‑specific affordability and organizational requirements. The projected compensation range for this position is $55,200.00 to $126,000.00 (annualized USD). The estimate displayed represents the typical salary range for this position and is just one component of Booz Allen’s total compensation package for employees. This posting will close within 90 days from the Posting Date.

Identity Statement

As part of the hiring process, we will ask you to complete an identity verification process that leverages advanced biometrics and artificial intelligence to ensure authenticity and protect against identity fraud. You are expected to be on camera during interviews and assessments. We reserve the right to take your picture to verify your identity and prevent fraud.

Candidate AI Usage Policy

AI is a part of our daily work at Booz Allen, and we are committed to the responsible and ethical use of AI tools. However, we want to ensure a fair candidate process based on your own skills and knowledge. As part of this commitment, the use of artificial intelligence (AI) or other tools to assist with responses during interviews (whether in‑person or virtual) is prohibited unless permission is explicitly provided.

Work Model
Our people‑first culture prioritizes the benefits of collaboration, whether it occurs in person or virtually. To support engagement and effective communication, employees working virtually are generally expected to have their cameras on during meetings.

• Remote: If this position is listed as remote, there may still be occasions when you are required to work in person at a Booz Allen or customer facility.

• Hybrid: If this position is listed as hybrid, you will be expected to work from a Booz Allen facility frequently, in alignment with leadership expectations and the needs of the role. You may also be required to work from or visit a customer facility.

• Onsite: If this position is listed as onsite, work will primarily be performed at a Booz Allen office or customer facility, where employees will collaborate directly with colleagues and customers as required by the role.

Commitment to Non‑Discrimination

All qualified applicants will receive consideration for employment without regard to disability, status as a protected veteran or any other status protected by applicable federal, state, local, or international law.