Joining Engineer

Location: Coven Heath

We are seeking an experienced Joining Engineer specializing in Cold Metal Transfer (CMT) welding and advanced joinery for high-volume automotive manufacturing. In this role, you will lead process development, parameter optimization, and continuous improvement across automated Body-in-White (BIW) and battery structure production lines.

You will focus on joining challenging materials—such as thin-gauge aluminum, ultra-high-strength steels (UHSS), and hybrid assemblies—while ensuring high line efficiency, minimal spatter, and strict safety-critical weld quality.

Key Responsibilities

* CMT Process Optimization:
Develop, qualify, and stabilize Fronius CMT welding parameters across automated BIW, chassis, or battery tray production lines.

* Robotic Cell Commissioning:
Fine-tune automated welding cells with multi-axis robots (KUKA, ABB, FANUC) for high-speed, repeatable automotive assembly.

* Defect Reduction & Line Support:
Perform root-cause failure analysis (porosity, burn-through, gap variation) and implement immediate counter-measures during pre-series and ramp-up phases.

* Design for Manufacture (DFM):
Work with BIW design teams to optimize automotive joint configurations, gap tolerances, and fixture design for optimal heat input control.

* Quality & Standards Compliance:
Ensure all joints comply with automotive OEM standards, creating Welding Procedure Specifications (WPS), PQR, and executing PFMEAs.

* Multi-Joining Technologies:
Support secondary BIW joining techniques where applied, such as Self-Piercing Riveting (SPR), Resistance Spot Welding (RSW), and structural adhesives.

Profile

Key Requirements & Qualifications

* Education:

Degree in Joining/Welding Engineering, Metallurgy, Mechanical Engineering, or equivalent automotive industry experience.

* Automotive Background:
Minimum 3+ years in automotive manufacturing, specifically within BIW, battery enclosure, or chassis production environments.

* CMT Expertise:
In-depth knowledge of Fronius CMT systems, pulse settings, and low-heat input welding of aluminum alloys and galvanized steels.

* Robotic Integration:
Hands-on experience programming and troubleshooting robotic MIG/MAG welding equipment.

* Core Quality Tools:
Proficiency in APQP, PPAP, 8D problem-solving, PFMEA, and metallographic weld testing (macrosections, cut-and-etch).

Desirable Experience

* Experience in EV/e-Mobility manufacturing (e.g., aluminum battery enclosure welding).

* Familiarity with automotive quality standards (IATF 16949, ISO 3834).

* Experience with automated optical weld inspection systems or inline monitoring tools