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. is seeking an experienced Welding Engineer/Process Specialist in Houston, TX to drive Resistance Seam Welding (RSEW) process development and qualification in line with AWS D17.2 and Nadcap requirements.

You will lead tooling design, metallurgical testing coordination, and operator qualification while ensuring tight process control and minimal heat-affected zone distortion in precision bellows assemblies.

Qualifications

• Bachelor’s degree with 2+ years resistance welding experience.
• Or associate degree with 5+ years RSEW experience in regulated environment.
• Experience developing and qualifying welding procedures per AWS D17.2.

Responsibilities

• Develop and optimize RSEW schedules for thin-gauge alloys.
• Lead Nadcap welding audits and compliance tasks.
• Design tooling to ensure repeatable weld quality.
• Lead operator qualification and training for resistance welding.

Skills

Welding procedures

Nadcap AC7110/4

AWS D17.2 knowledge

Blueprint reading & AS9100

Welding controls & calibration

Education

Bachelor’s Degree in Welding Engineering / Materials Science / Metallurgy / Mechanical Engineering

Associate Degree in Welding Technology / Manufacturing Technology

Tools

Weld monitors

Current/energy feedback systems

Calibration procedures

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