Welding Engineer

Bellows Systems, Inc. · Houston, United States

Your welds will fly

BSI makes the metal bellows used in spacecrafts, space launch vehicles, missile systems, and aircrafts, built from foil and thin-gauge alloys, where one bad weld is not an option. You will own the weld process, set the parameters, write the procedures, and see your work on real flight hardware. If you have ever looked at a weld schedule and known exactly why it blew through, we want to talk.

The Problem You Will Solve:

Welding is our most important process and our biggest opportunity. You will own first pass yield on thin wall welds: finding the root cause for defects, tightening parameter windows, and building schedules, fixtures and work instructions that make good welds repeatable.

In your first 12 months, we expect you to:

• Reduce NDT rejection rates.
• Cut weld-related rework hours.
• Qualify and release new or revised welding schedules and WPS documents.
• Support our next Nadcap audit with clean, audit-ready records.

Responsibilities:

• Own welding processes: define parameter windows, qualify new schedules and specifications, write work instructions and design welding fixtures.
• Lead root cause analysis on blow-through, porosity, cracking, incomplete fusion, and NDT rejects, and drive corrective action to closure.
• Develop, qualify, and maintain WPS and PQR documentation to AWS D17.1, AWS D17.2, and ASME Section IX.
• Support Nadcap accreditation, audits, and corrective actions.
• Run controlled experiments and process verification, and keep detailed records of trials, test results, dimensional inspection, and design iterations.
• Work with design and quality engineers on first article and new product welds, and contribute to design reviews for weldability.
• Train and support operators and technicians on process changes.

Required Qualifications

• Bachelor's or Master's degree in Welding Engineering, Materials Science, Metallurgy or a related field. Significant prior GTAW process development and WPS creation experience may be accepted in place of a degree. Please show your WPS and PQR experience on your resume, including processes, materials and codes.
• Experience writing, developing and qualifying welding procedure specifications and schedules for fusion welding, resistance welding or both.
• Working knowledge of AWS D17.1, AWS D17.2 and ASME Section IX.
• Practical experience with thin gauge nickel alloys (Inconel 625 and 718, Hastelloy), 300 series stainless steels and titanium.
• Strong technical writing skills for code-specific documentation.
• Ability to read mechanical drawings. Familiarity with bellows, tubular components or sheet metal forming is a plus.
• A methodical, critical thinker who works well in a fast paced, deadline driven environment.
• Ability to read, write and speak English, and to lift 50 lbs from floor to waist, with or without reasonable accommodation.

Preferred Experience

• Metallurgy and metallographic inspection: 3 years
• WPS, PQR and schedule development: 3 years
• Resistance seam and spot welding: 2 years
• Gas tungsten arc welding (GTAW): 2 years
• Micro plasma and plasma welding on thin foil: 1 year
• NDT literacy: FPI, radiography and helium leak testing
• Nadcap audit participation

Desired overall experience is 2 to 5+ years. No resistance seam welding experience? We provide machine specific training, including on resistance seam welding, for candidates with a strong fusion welding foundation.

Work Environment

Split between engineering workstations, and active shop floor. Safety training and equipment are provided.

About Bellows Systems, Inc.

Bellows Systems, Inc. (BSI) makes precision metal bellows and expansion joints for spacecraft, launch vehicles and aircraft. You will work directly with engineering and operations leadership, not behind layers of management.

Export Compliance

This position requires access to export controlled technical data. Applicants must be a U.S. Person as defined under the International Traffic in Arms Regulations (ITAR). BSI cannot transfer or sponsor a work visa or employment authorization for this position.

Equal Opportunity

BSI is an equal opportunity employer. We consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability or veteran status, and we provide reasonable accommodation to qualified individuals with disabilities.