Sr. Principal Welding Manufacturing Engineer

Position Summary:
BAE Systems is searching for a seasoned Sr. Principal Welding Manufacturing Engineer to bolster our engineering team in Louisville, Kentucky. The role involves providing engineering and technical support for welding operations in the fabrication and manufacture of products used in critical defense applications. You will undertake research, develop concepts, designs, materials, functions, and performance parameters, and conduct robust testing and modification of products. As a Sr. Principal Welding Manufacturing Engineer, you'll prepare and lead weld engineering analysis and documentation, tests, examinations, performance and procedure qualifications to meet customer requirements. Additionally, you will research and recommend welding equipment, assess their capabilities, and aid in developing welding standards and specifications. With a focus on quality, collaboration across teams, and technology that supports our warfighter, this role on a 9/80 schedule—providing every other Friday off—is perfect for a professional who thrives in a cohesive environment driven by innovation and excellence in defense technology.

Key Responsibilities:

• Create processes for fabrication, testing, assurance of weld integrity, and delivery of products.
• Coordinate with multiple teams across various functions to support operations.
• Analyze Non-Destructive Testing (NDT) inspection reports for root cause and provide plans for production repair.
• Recommend welding equipment and automation solutions to minimize defects and enhance consistency.
• Conduct weld engineering analysis and participate in weld procedure and performance qualifications.
• Apply knowledge of metallurgy, welding robotics, programming, and material weldability to improve or create processes.
• Review supplier offerings to ensure product compliance with government specs.
• Develop welding standards, specifications, and repair procedures.
• Manage non-conformances and lead Root Cause and Corrective Action activities.
• Create and revise technical documentation, contributing to professional publications or presentations.
• Organize and populate Manufacturing Engineering production information using Microsoft Office tools.
• Formulate work documentation, including routings and instructions to guide the welding workforce.
• Apply and interpret welding specifications for active projects.

Qualifications:

• Bachelor's degree in Weld Engineering, Weld Engineering Technology, Mechanical Engineering, Metallurgy, or related discipline plus 10 years of experience in a manufacturing environment.
• Consideration for candidates with a 2-year degree and 15 years of relevant hands-on experience.
• Experience with digital equipment for weld parameter tracking.
• Knowledge of NDT inspection techniques and results interpretation.
• Familiarity with consumables and base material specifications concerning welding.
• Proficiency with SAW, GMAW, SMAW, and GTAW welding processes.
• Experience in creating work instructions and rework procedures for production operations.
• Familiarity with CAD programs and model manipulation.
• Understanding of welding and manufacturing equipment and technologies.

Preferred Qualifications:

• Master of Science Degree in Engineering.
• AWS CWI certification or other relevant qualifications.
• Bachelor's degree in Weld Engineering or similar field and NDT Level II certification.
• Defense contractor experience.
• Experience with robotic automation including cobots.
• Knowledge of NAVSEA and other government welding and inspection requirements.

Work Environment and Physical Requirements:

• The role demands full-time onsite presence with travel less than 10%.

Reporting:
The Sr. Principal Welding Manufacturing Engineer will report to the Engineering Management at the Louisville facility.

Location:
Louisville, Kentucky, United States

Benefits:

• Health, dental, and vision insurance
• Health savings accounts
• 401(k) savings plan with company match
• Disability coverage and life and accident insurance
• Employee assistance and legal plans
• Various insurance discounts
• Paid time off, holidays, and other types of leave including parental, military, and bereavement
• Company recognition program and applicable incentives

Job Category:
Chief Engineer / Port Engineer

Experience Required:
10 years with a Bachelor’s degree or 15 years with a 2-year degree.

Pay Range:
$118,504 - $201,457 per year