Welding Engineer

Job Number: R0246871

About the role

Develop welding techniques, procedures, and application of welding experiments to resolve metal fabrication challenges. Conduct research and development to test new fabrication processes, improve or develop new welding equipment, and evaluate emerging technologies such as metallic additive manufacturing and solid-state processes. Validate mechanical testing, metallurgical assessments, and interpret Non-Destructive Testing (NDT) results.

Participate in and monitor testing, models, and simulation efforts, develop test plans, and analyze test results to determine system performance and recommend corrective actions. Establish welding procedures to aid in specification restrictions, advanced material processing, and pre- and post-heating requirements for complex alloys and critical joints. Ensure compliance with established welding procedures and standards and oversee weld testing for conformance with national and military code requirements.

Lead and coordinate multi-disciplinary project teams in the execution of advanced welding, materials joining, and research and development activities. Develop technical reports based on research and development efforts and failure analysis investigations and oversee schedules and milestones to ensure engineering solutions and deliverables align with mission objectives.

Responsibilities

• Develop and implement welding techniques and procedures to resolve metal fabrication challenges
• Conduct research and development for new fabrication processes, welding equipment, and emerging technologies (e.g., metallic additive manufacturing, solid-state processes)
• Validate mechanical testing, metallurgical assessments, and interpret Non-Destructive Testing (NDT) results
• Participate in testing, modeling, and simulation efforts; develop test plans and analyze results to recommend corrective actions
• Establish welding procedures for specification restrictions, advanced material processing, and pre/post-heating requirements for complex alloys and critical joints
• Ensure compliance with welding procedures and standards; oversee weld testing for national and military code conformance
• Lead and coordinate multi-disciplinary project teams in advanced welding, materials joining, and R&D activities
• Develop technical reports based on research, development, and failure analysis investigations
• Oversee schedules and milestones to align engineering solutions with mission objectives

Requirements

• 5+ years of experience as a welding engineer
• Experience as a technical lead troubleshooting, diagnosing, and resolving complex welding production bottlenecks, defect root-causes, and challenges
• Experience with Computer Aided Engineering (CAE) tools and Finite Element Analysis (FEA) to model weld distortion, residual stresses, and thermal cycling to optimize weld joint design
• Experience implementing weld joint optimizations, process efficiency improvements, and material rationalization
• Experience with research, development, and implementation of cutting-edge joining technologies, including metallic additive manufacturing, solid-state joining, and programming automated or robotic welding systems for heavy structures
• Experience interpreting and applying American Welding Society (AWS) structural codes to heavy manufacturing
• Knowledge of welding processes and industry applications
• Ability to obtain a Secret clearance
• Bachelor’s degree in welding engineering, materials engineering, or mechanical engineering

Preferred Qualifications

• Knowledge of the physical and mechanical metallurgy of complex materials used in ground vehicles
• Knowledge of military combat and tactical vehicle welding specifications and requirements
• Knowledge of DoD quality assurance, acceptance sampling, and non-destructive evaluation acceptance as they pertain to complex welded structures
• Master’s degree in welding engineering or materials science
• AWS Certified Welding Engineer (CWEng) Certification

Benefits

• Health, life, disability, financial, and retirement benefits
• Paid leave, professional development, tuition assistance, work-life programs, and dependent care
• Recognition awards program for exceptional performance and superior demonstration of company values

Full-time and part-time employees working at least 20 hours a week on a regular basis are eligible to participate in Booz Allen’s benefit programs. Individuals that do not meet the threshold are only eligible for select offerings, not inclusive of health benefits.

Pay

The projected compensation range for this position is $55,200.00 to $126,000.00 (annualized USD). Salary is determined by various factors, including location, education, knowledge, skills, competencies, experience, contract-specific affordability, and organizational requirements.

Schedule

This posting will close within 90 days from the posting date.

Work model expectations:

• Remote: Generally virtual, with occasional in-person work at a Booz Allen or customer facility.
• Hybrid: Frequent work from a Booz Allen facility, with potential customer facility visits as needed.
• Onsite: Work primarily performed at a Booz Allen office or customer facility, with direct collaboration required.

Employees working virtually are generally expected to have their cameras on during meetings to support engagement and effective communication.