TE - HV Battery Welding at Ford Global Career Site

Dearborn, Michigan, United States -

Full Time

Start Date

Immediate

Expiry Date

11 Feb, 26

Salary

0.0

Posted On

13 Nov, 25

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Welding, Laser Welding, Ultrasonic Welding, TIG Welding, MIG Welding, Material Selection, Joint Design, Process Capability, Failure Mode Avoidance, Data Analysis, Communication, Presentation, Analytical Skills, Interpersonal Skills, Design for Manufacturing, Testing

Industry

Motor Vehicle Manufacturing

Description

The batteries in the electrified propulsion system rely heavily on their structural system to maintain battery cell integrity for performance and durability. This requires a challenging structural design with unique hardware to deliver. Current industry solutions involve using welding techniques to join materials to improve robustness, manufacturing cycle time, and optimal package space. Laser welding is becoming one of the most common welding techniques seen in HV Battery manufacturing. The structural and welding design and requirements must be developed with a focus on function and failure mode avoidance including material selection, joint design, process capability, and process failure modes. Deep technical understanding is necessary regarding the welding processes (laser, TIG, MIG, Ultrasonic), weld joint design, material compatibility, welding process design/control, design for manufacturing, and testing. Not only is welding critical for structural design, but welding has become a given in cell-to-cell electrical connections, voltage sensing connections, and internal cell construction. Whether part of an array based or cell to pack solution, welding has become a staple in joining techniques within the industry. Establishment and maintenance of Ford's technical know-how, processes, foundation engineering documents, and quality documents warrant a technical expert role dedicated to their development and management. A technical expert position to lead these HV Battery welding activities and deliver the high quality, performance, and safety is critical to delivering Ford's electrification future at the right value. For Electrified Powertrain Engineering Related structural, cell tab, cell to bus bar, voltage sense lead, and internal cell welding: Lead the technical assessment sign-off of HV battery internal welding performance via deep dive reviews, fit and function reviews, checklist evidence, deviation requests and milestone sign-off. Lead the development of new and update requirements, design rules, DVP, and test methods associated with welding and drive the transition from Engineering Specifications to corporate standard engineering documents in FEDE. Lead development and maintenance of welding failure mode avoidance foundation documents. Provide technical leadership to field resolution Lead the development, formalization and dissemination of welding strategies, processes, and issue resolution tool sets. Lead the development of new technologies, methods, and material applications, engaging non-Electrified Propulsion Engineering organizations as needed to deliver the best welding solutions that maximize value for the company. Develop and improve the interfaces the structural community and associated engineering process in the vibration and crash attributes Support the evolution from physical evaluations toward analytical evaluations of welding systems. Support the creation of ESOWs and RFIs/RFQs and supplier visits/reviews. Be a single global point of contact for welding delivery internally and with full-service suppliers. Lead the development of training material and the education of Ford engineers in relation to welding topics. Support competitive benchmarking and research activities. Collaborate globally with the Ford technical community to foster communication, process improvements, and advancements. Established and active employee resource groups Bachelor of Science in Welding, Electrical, or Mechanical Engineering 5+ years laser and ultrasonic welding in automotive or similar field experience Strong mechanics of materials background Resistance welding: Spot welding, seam welding (especially for tabs, bus bars and cell connections). Understanding parameters like current, voltage, force, and pulse time. Laser Welding: Pulsed laser welding, continuous laser welding. Understanding power speed, focus, and shielding gas Ultrasonic welding: Understanding amplitude, force, and time Ability to select appropriate welding methods and parameters based on material type, thickness, and joint design. Expertise in welded joint design for various functions and failure mode avoidance Expertise in welding process control methods and associated metrics Experience with vision systems or other inspection technologies integrated into welding processes Experience with process set-up, optimization, and validation. Experience with destructive testing methods like pull/shear testing and understanding results. Experience with non-destructive testing methods (like resistance testing and X-ray inspection and cross section analysis) to demonstrate quality Experience in development of requirements, design rules, and test methods Experience in helping resolve field issues associated with welding Experience working with D&R engineering, CAE analysis, and testing teams across multiple organizations Working knowledge of the GPDS milestones and timing, their deliverables, and evidence required as it relates to welding design and process development Strong data analysis skills Excellent communication, teaching, presentation, and analytical skills. Broad interpersonal skills, enabling team facilitation and effective interfacing with cross-functional teams Candidates must be able to work under operational pressures and to set priorities for themselves and for team members Experience developing and evaluating new concepts and design ideas desired MS in Welding, Electrical, or Mechanical Engineering preferred Strong working relationships with global counterparts in Battery Manufacturing Engineering, STA, structures, and industry desired Experience developing and evaluating new concepts and design ideas desired For more information on salary and benefits, click here: https://fordcareers.co/LL6SP2 Visa sponsorship is not available for this position. Verification of employment eligibility will be required at the time of hire.

Responsibilities

Lead the technical assessment and development of HV battery welding processes and requirements. Provide technical leadership and collaborate globally to ensure high quality, performance, and safety in welding activities.