Welding and Joining Engineer

Welding and Joining Engineer at Toyota Material Handling

Toyota Material Handling North America is seeking an experienced Welding Engineer / Joining Engineer to play a key role in advancing electrified powertrains and next‑generation energy storage systems for material handling equipment. In this hands‑on role, you’ll develop and industrialize cutting‑edge joining processes, including laser welding, resistance welding, and brazing as well as NDE (non‑destructive evaluation) techniques, that enable high‑performance lithium‑ion battery packs and fuel cell systems.

You’ll work closely with mechanical, electrical, manufacturing, and quality teams to ensure TMHNA delivers safe, reliable, and production‑ready solutions for next‑generation energy systems.

This role sits at the intersection of welding engineering, materials science, manufacturing engineering, and failure analysis, offering a unique opportunity to shape the next generation of advanced energy systems.

• Welding, Joining Technology & Metallurgical Engineering
• Develop and optimise joining processes, including laser welding, brazing, and bonding, for energy storage applications.
• Lead metallurgy‑driven process development for Aluminium, Copper and high‑strength steels.
• Perform metallurgical evaluations, including microstructure analysis, Heat‑Affected Zone characterization, hardness testing and weld sectioning.
• Conduct weld trials, define process windows, evaluate joint quality and ensure long‑term reliability based on material behaviour.
• Partner with equipment suppliers to specify welding systems, tooling, jigs, fixtures and automation.
• Support the development of joining processes used in battery pack enclosures, busbars, cooling plates and electro‑mechanical interfaces.
• Non‑Destructive Evaluation (NDE) Development
• Drive the lock‑step introduction of NDE techniques alongside new joining processes, ensuring inspection strategies are fully embedded before manufacturing scale‑up.
• Develop NDE solutions such as X‑ray/radiography, vision inspection and weld‑quality monitoring tools.
• Validate NDE methods for repeatability, capability and suitability for both prototype and high‑volume manufacturing.
• Implement NDE techniques that prevent scrap and reduce dependence on destructive testing.

• Manufacturing Process Development & Support
• Industrialise joining and inspection processes into manufacturing using structured process validation, tool qualification, PFMEA/DFMEA, SPC and DOE.
• Support prototype builds and transition joining processes to pilot lines and production environments.
• Troubleshoot process issues involving weld quality, materials behaviour, design interactions or equipment variation.
• Conduct capability studies, GR&R, weld parameter optimisation and statistical analysis to ensure process robustness.
• Failure Analysis & Reliability Engineering
• Lead structured failure analysis for weld‑related or materials‑related issues, including fractography, fatigue, cracking and corrosion mechanisms.
• Document findings in clear technical reports and communicate results to engineering, quality and manufacturing partners.
• Cross‑Functional Collaboration & Innovation
• Collaborate with Mechanical Engineering, Electrical Engineering, BMS, Manufacturing, Validation and suppliers to ensure fully integrated joining solutions.
• Maintain awareness of new welding, joining and NDE technologies, introducing innovations that strengthen TMHNA’s competitiveness.
• Support both laboratory and production environments to execute trials, inspections and troubleshooting.
• Domestic travel expected ~20%

• B.S. in Welding Engineering, Mechanical Engineering, Materials Science or related discipline.
• 10+ years of welding engineering, welding research or NDE experience.
• Experience welding Copper, Aluminium or high‑strength steels.
• Experience with NDE techniques, including X‑ray or ultrasonic inspection.
• Demonstrated capability in data analysis, documentation and experimental interpretation.
• Strong communication, teamwork and interpersonal skills.
• Self‑starter capable of managing complex, multi‑disciplinary assignments.
• Passion for innovation and continuous improvement.