Senior Electron Beam Welding Engineer

Description

• Develop and execute weld qualification plans, including test coupons and validation trials, in coordination with quality and materials teams
• Provide hands-on training and mentorship to welding technicians and operators on EBW techniques, safety protocols, and industry best practices.
• Analyze weld test data to identify trends, determine root causes of defects, and implement corrective actions to enhance welding performance and reliability.
• Reading and interpreting hazardous warning signs
• Occasionally requires extended hours to support launch and critical project timelines
• Communicating with others to exchange information
• Partner with design engineers, production teams, and key stakeholders to integrate EBW processes into the manufacturing workflow effectively.
• Repetitive assembly operations of manufacturing test fixtures and test setups in collaboration with engineering and manufacturing teams
• Reporting issues with equipment or unsafe conditions
• Prioritizes and ensures safety of oneself and others.
• Accessing the accuracy, neatness and thoroughness of the work assigned
• Lead continuous improvement initiatives to optimize EBW processes, increase efficiency, reduce cost, and maintain high-quality output.
• Setting up and transferring temporary structures (e.g. scaffolding, ladders)
• Operating motor vehicles, heavy equipment or machinery
• Use hand tools
• Develop and maintain comprehensive technical documentation, including process instructions, work procedures, and detailed reports.
• Ensure performance, reliability, and availability of EBW systems, including high-vacuum chambers, beam control units, and power supplies.
• Oversee and review EBW inspections to verify compliance with design specifications and applicable quality standards.
• Monitor and calibrate critical parameters (e.g., beam alignment, focus, power output, vacuum integrity) to maintain process consistency and compliance with specifications.
• Design, develop, and maintain EBW procedures and supporting documentation (WPS/PQR) to meet material, joint, and quality requirements in compliance with applicable codes, standards (e.g., AWS, ASME, API), and regulatory expectations.
• Ensure accurate recordkeeping of EBW procedures, inspection results, and quality control data to support traceability and continuous improvement.
• Anticipate future welding needs by aligning EBW procedures and qualification strategies with evolving product designs, manufacturing processes, and regulatory demands.
• Lead maintenance and upgrade initiatives, including preventive planning, troubleshooting, vendor coordination, and system improvements to enhance automation and long-term equipment reliability.
• Adjusting, moving, transporting, installing, positioning, or removing objects up to 50 pounds in all directions

Requirements

• Ability to collect, manage, and transfer technical knowledge across teams or documentation systems
• Strong knowledge of EBW processes, high-vacuum systems, and high-voltage equipment operation
• Ability to solve problems quickly and efficiently.
• Hands-on experience working with austenitic stainless steels, carbon steels, piping systems, and pressure vessels
• Moving self in different positions to accomplish tasks in various environments including tight and confined spaces
• Skilled in using CAD software such as SolidWorks for part modeling and drawing generation
• Ability to seek different and novel ways to create efficiencies when working on problems, challenges and issues.
• Familiarity with ASME Boiler and Pressure Vessel Code and AWS structural welding standards
• Familiarity with the calibration, preventive maintenance, and troubleshooting of EBW systems and associated instrumentation.
• Ability to work with highly collaborative team.
• Proficient in reading and interpreting complex engineering and assembly drawings, including weld symbols and geometric dimensioning & tolerancing (GD&T)
• High-concentration, demanding and fast-paced
• Occasionally requires non-standard work-week hours
• Minimum 5 years of welding engineering experience, with substantial hands-on experience in EBW required
• Experience with manual and CNC machining operations is preferred
• Excellent verbal and written communication skills; able to collaborate effectively across engineering, production, and quality teams
• Some travel may be required (up to 20%) to other Kairos Power offices or external suppliers
• Proven ability to manage multiple priorities in a fast-paced, agile manufacturing or development environment
• Remaining in a stationary position, often standing, or sitting for prolonged periods
• Bachelor’s degree or higher in Welding Engineering, Materials Science, Mechanical Engineering, or a related technical field
• Wearing proper PPE, to include face mask, face shields, gloves, safety shoes, etc.
• Proficient with computers and digital tools used in technical documentation, data analysis, and process development
• Ascending or descending ladders, stairs, scaffolding, ramps, scissor lifts, articulated boom lifts and the like
• Strong problem-solving skills and ability to drive continuous improvement through data-driven analysis and collaboration
• Experience with weld inspection methods, including both destructive testing and non-destructive examination (NDE) techniques
• Experience leading cross-functional projects or mentoring junior engineers and technicians is preferred.

Benefits

• Elevated heights
• 401(k) and pre-tax health insurance, dependent care, and commuter benefits (FSA)
• Low temperatures
• Occasionally requires working weekends
• Competitive compensation packages
• Paid Vacation
• Occasionally requires overtime
• High temperatures
• Medical, dental and vision benefits for employees and their dependents

Training + Development

Interview process

Visa Sponsorship

Security clearance