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Senior Welding Engineer

Aalo· Engineering
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Austin, TXfull-timePosted 5mo ago

About the role

Founding member of the welding engineering function responsible for process development, qualification, automation, cost reduction, and R&D into advanced welding modalities (laser beam, electron beam, and others) to support nuclear vessel applications and zirconium welding capability from scratch.

Responsibilities

  • Develop, qualify, and optimize GTAW, GMAW, spray MIG, and emerging processes for stainless steel pressure vessels and piping
  • Own WPS/PQR documentation to ASME Section IX, AWS D1.6, or applicable codes
  • Lead zirconium welding procedure development: inert atmosphere GTAW, shielding gas optimization, contamination control, and full mechanical qualification
  • Develop and document PWHT cycles; interpret metallurgical outcomes
  • Evaluate and qualify laser beam (LBW), electron beam (EBW), plasma arc (PAW), and hybrid laser-arc processes for vessel and pressure system applications
  • Design parametric studies to characterize process windows and build qualification datasets
  • Develop solutions for difficult joint configurations — dissimilar materials, thin-wall closures, complex penetrations
  • Collaborate with vendors, equipment suppliers, and national lab partners to stay at the front edge of nuclear-relevant welding technology
  • Build internal IP and documentation to support future procedure qualifications and regulatory submittals
  • Identify and implement orbital GTAW, mechanized MIG, and robotic welding to drive consistency and reduce labor cost
  • Develop parametric programs for automated systems including seam tracking, adaptive fill, and multi-pass sequencing
  • Instrument in-process monitoring (voltage, travel speed, heat input) to enable closed-loop quality control
  • Track weld cycle times, consumable costs, and rework rates; use data to justify capital investments
  • Partner with design engineers on joint weldability — distortion control, access, inspection compatibility
  • Work with NDE personnel (RT, PT, UT, PAUT) to interpret results and close nonconformances
  • Drive root cause analysis on weld defects using metallography, fractography, hardness, and chemical analysis
  • Build and maintain weld quality metrics; use them to focus engineering effort where it has the highest return
  • Maintain documentation infrastructure: travelers, hold points, NCRs, lessons learned
  • Provide real-time direction to welders on the floor; troubleshoot defects and maintain build pace
  • Mentor welders on technique, procedure compliance, and quality standards
  • Support welder qualification and certification as the team scales

Qualifications

  • BS in Materials Science, Metallurgical Engineering, Mechanical Engineering, or related field
  • 5+ years of welding engineering experience including process development and qualification
  • Hands-on GTAW experience on stainless steel pressure-boundary applications
  • Working knowledge of ASME BPVC Section IX or equivalent pressure systems code
  • Comfortable on the shop floor — able to evaluate welds in progress, not just on paper

Skills

Required:GTAW (TIG)GMAW (MIG)WPS/PQR development
Nice to have:Welding of zirconium

Benefits

  • Competitive salary based on technical level
  • Health, Dental, and Vision Insurance
  • Paid Time Off
  • Corporate Gym Membership
Last updated Sep 10, 2026. Interested? Apply on the company site.

About Aalo

Welcome to the dawn of a Second Atomic Age

Creating abundant and dependable clean energy to power humanity for generations.

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