Joining Engineer at Segula Technologies, 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.