Technical Expert - HV Battery Welding

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 Released 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…