Overview
We are seeking an experienced CMT Welding / Joining Engineer to provide specialist technical support within a Body in White manufacturing environment.
The successful individual will have strong hands-on expertise in Cold Metal Transfer (CMT) welding, ideally using Fronius welding systems, together with a detailed understanding of GMAW / MIG / MAG welding processes.
This is a specialist engineering requirement focused on process development, optimisation, troubleshooting, commissioning and production support rather than a production welder position.
The engineer will support the development and industrialisation of robust welding processes, resolve complex joining issues and work closely with manufacturing teams, equipment suppliers and automation integrators.
Key Responsibilities
- Provide subject-matter expertise for Cold Metal Transfer welding applications within Body in White manufacturing.
- Develop, optimise and validate CMT / GMAW welding processes and operating parameters.
- Establish robust welding process windows covering current, voltage, wire feed speed, travel speed, shielding gas and heat input.
- Investigate welding defects and production concerns including porosity, lack of fusion, distortion, burn-through, penetration and weld instability.
- Perform structured root-cause analysis and implement effective corrective actions.
- Support robotic welding cell installation, commissioning, debugging and production launch.
- Optimise robot paths, torch orientation, welding sequences and process cycle times.
- Support welding trials, Design of Experiments and process capability studies.
- Evaluate weld quality using appropriate destructive and non-destructive testing methods.
- Support macro-sectioning, weld penetration assessment and metallurgical analysis where required.
- Develop and maintain welding specifications, process documentation and technical standards.
- Support PFMEA, Control Plans and manufacturing quality documentation.
- Work closely with equipment manufacturers, automation integrators and joining technology suppliers.
- Provide technical input into welding equipment selection and process feasibility reviews.
- Support FAT, SAT, equipment buy-off and production readiness activities.
- Resolve production and launch issues relating to welding equipment, tooling and joining processes.
- Identify opportunities to improve weld quality, reliability, cycle time and manufacturing efficiency.
- Provide technical guidance and knowledge transfer to manufacturing and engineering teams.
Essential Experience
Candidates should demonstrate strong practical experience in:
- Cold Metal Transfer welding.
- Fronius CMT welding technology or equivalent advanced GMAW systems.
- GMAW / MIG / MAG welding processes.
- Welding process development and parameter optimisation.
- Robotic welding systems.
- Welding cell commissioning and production support.
- Weld defect investigation and root-cause analysis.
- Automotive, Body in White or high-volume manufacturing environments.
- Thin-gauge sheet-metal welding.
- Working independently as a technical welding or joining specialist.
Highly Desirable Experience
Preference will be given to candidates with experience in:
- Fronius TPS/i or TPS welding platforms.
- Aluminium welding.
- Aluminium Body in White structures.
- Dissimilar material joining.
- Galvanised and coated steels.
- Advanced High Strength Steel.
- KUKA, ABB, FANUC, Comau or Yaskawa robotic systems.
- Robot programming, TCP calibration and weld path optimisation.
- Weld metallurgy and Heat Affected Zone analysis.
- Destructive and non-destructive weld testing.
- Design of Experiments.
- Cp / Cpk and process capability studies.
- PFMEA and Control Plans.
- Manufacturing equipment commissioning.
- Automotive production launch and industrialisation.
- Supplier and automation integrator management.
Additional Joining Knowledge
Broader experience across automotive joining technologies would be advantageous, including:
- Resistance spot welding.
- MIG brazing.
- Laser welding or laser brazing.
- TIG welding.
- Structural adhesives.
- Self-Piercing Riveting.
- Flow Drill Screws.
- Clinching or mechanical joining technologies.
Qualifications
A relevant engineering qualification would be preferred in one of the following disciplines:
- Welding Engineering
- Manufacturing Engineering
- Mechanical Engineering
- Materials Engineering
- Metallurgy
- Production Engineering
Additional welding qualifications such as IWE, EWE, IWT, CSWIP or equivalent would be advantageous but are not essential where substantial relevant industry experience can be demonstrated.
Candidate Profile
The ideal candidate will be an experienced welding or joining engineer who combines strong theoretical knowledge with practical manufacturing experience.
They should be capable of independently diagnosing complex welding problems, developing technical solutions and supporting those solutions through validation and implementation within a production environment.
The individual should be comfortable working directly with manufacturing engineers, production teams, equipment suppliers and automation integrators and should be able to communicate technical issues clearly to both engineering and operational stakeholders.
Pay: £30.00-£40.00 per hour
Work Location: In person
