Welding Engineer / Process Specialist – Resistance Seam Welding (RSEW)

Bellows Systems, Inc.; Houston (TX); On-site; USD 85,000 - 115,000; Full time

Job summary

Bellows Systems, Inc. in Houston, TX seeks an experienced Welding Engineer / Process Specialist focused on Resistance Seam Welding (RSEW) to support our precision bellows and flexible metal conduit manufacturing operations.

This role leads process development, schedules qualification, operator training, and Nadcap/AWS D17.2 compliance, with emphasis on welding quality, tooling design, metallurgical testing, and continuous improvement on the shop floor.

Qualifications

• Bachelor’s degree with 2+ years resistance welding experience, or associate degree with 5+ years direct RSEW experience.
• Experience developing/qualifying welding procedures to AWS D17.2.
• Prior Nadcap welding audits lead or participation.

Responsibilities

• Develop, qualify, and optimize RSEW schedules for thin-gauge alloys used in bellows.
• Establish WPS and PQR per AWS D17.2 Class A/B/C requirements.
• Lead Nadcap AC7110/4 audits and RCCA actions.
• Design tooling/fixturing to ensure repeatable welds and minimal HAZ distortion.
• Coordinate metallurgical testing and verify joint integrity.
• Lead shop-floor operator qualification and training in resistance welding.

Skills

Resistance seam welding

AWS D17.2

Nadcap AC7110/4

Welding procedure development

AS9100 / quality systems

Blueprints & GD&T

Root cause analysis (5-Why), SPC

Education

Bachelor's degree in Welding Eng / Materials Science / Metallurgy / ME

AS in Welding Technology / Manufacturing Technology

Tools

Weld monitoring systems

Fixture design & tooling collaboration

RSEW equipment operation

Job description

Job Summary:

Welding Engineer: Houston, TX We are seeking an experienced Welding Engineer / Process Specialist focused on Resistance Seam Welding (RSEW) to support our precision bellows and flexible metal conduit manufacturing operations. This role is responsible for process development, schedule qualification/optimization, training, and technical compliance in accordance with AWS D17.2 and Nadcap (AC7110/4) requirements.

Duties and Responsibilities:

• Process Development & Parameter Optimization: Develop, qualify, and optimize Resistance Seam Welding (RSEW) schedules for thin-gauge nickel alloys (Inconel 625/718, Hastelloy), stainless steels (300-series, 321, 316L), and titanium used in flexible bellows assemblies.
• Specification Compliance (AWS D17.2): Establish, document, and maintain Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) in strict alignment with AWS D17.2 Class A, B, and C requirements.
• Nadcap Accreditation: Serve as the technical lead for Nadcap welding audits (AC7110 and AC7110/4 for Resistance Welding). Manage compliance matrices, pre-audit gap analyses, and prompt corrective actions (Root Cause & Corrective Action / RCCA).
• Tooling & Fixturing Design: Collaborate with tooling and design teams to engineer precision electrode wheels, chill rings, expanding mandrels, and alignment fixtures to ensure repeatable setup, consistent weld quality, and minimal heat-affected zone (HAZ) distortion.
• Metallurgical & Mechanical Testing: Coordinate metallographic preparation and evaluate metallographic cross-sections, micro-hardness profiles, peel/shear tests, and pressure/burst tests to verify joint integrity and weld nugget overlap per drawing and specification requirements.
• Shop Floor Support & Operator Qualification: Lead training, technical oversight, and formal performance qualification of resistance welding operators in accordance with aerospace standards.
• Continuous Improvement: Troubleshoot weld defects (e.g., expulsion, cracking, porosity, incomplete fusion) using root-cause analysis methodologies, 5-Why, and Statistical Process Control (SPC).

Qualifications / Requirements:

Education & Experience:

• Bachelor’s Degree in Welding Engineering, Materials Science, Metallurgy, or Mechanical Engineering with 2+ years of hands‑on resistance welding experience; OR
• Associate Degree in Welding Technology / Manufacturing Technology with 5+ years of direct experience programming, qualifying, and troubleshooting Resistance Seam Welding (RSEW) equipment in a regulated manufacturing environment.

Technical Competencies:

• Direct experience developing and qualifying welding procedures to AWS D17.2 (Specification for Resistance Welding for Aerospace Applications).
• Proven track record participating in or leading Nadcap AC7110/4 (Resistance Welding) audits and compliance tasks.
• In-depth understanding of resistance welding controllers (e.g., weld monitors, constant current/energy feedback, secondary monitoring systems) and machine calibration procedures.
• Familiarity with thin-walled tubular components, expansion joints, or hydroformed/edge-welded bellows geometries is highly preferred.
• Strong background in blueprint reading, GD&T, and AS9100 quality management system requirements.
• Certified Welding Engineer (CWEng) or ASQ certification is an asset.

Work Environment:

• Split between office engineering workstations, metallurgical testing labs, and active shop floor environments.
• Ability to inspect precision weld samples under magnification and review macro/micrographs.
• Must be a U.S. Citizen or Permanent Resident (Green Card holder) due to export compliance (ITAR/EAR) requirements.

Job Location:

• Houston, Texas
• 100% On-site

FLSA Status:

Full-time, Exempt