TE HV Battery Welding

Fords Electric Vehicles Digital and Design (EVDD) team is charged with delivering the companys vision of a fully electric transportation future. EVDD is customer-obsessed entrepreneurial and data-driven and is dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. Youll join an agile team of doers pioneering our EV future by working collaboratively staying focused on only what matters and delivering excellence day in and day out. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

In this position...

What youll do...

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 Fords 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 Fords 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.

Youll have...

• 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

• Expertise in battery welding process fundamentals

  • 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

  • Understanding of spatter free zones
  • Understanding of CQI-15 and 2D drawing requirements for welds
  • Knowledge of electrical principles related to battery connections and resistance to support efficient and robust design
  • Awareness of relevant industry standards (e.g. safety standards quality standards like ISO 9001 or specific automotive/aerospace standards if applicable).
  • Strong mechanics of materials background and welding metallurgy

• Expertise in welding process control methods and associated metrics

  • Knowledge of Statistical Process Control (SPC) principles and Key Process Input Variables of welding process.
  • Experience with vision systems or other inspection technologies integrated into welding processes
  • Understanding of fixturing requirements for precise and repeatable welding
  • Experience with process set-up optimization and validation.

• Expertise in Welding Quality control methods

  • 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

• Foundation

  • Strong experience in developing foundation documents (DFMEA P Diagram B Diagram SCCAF etc.)
  • Experience in development of requirements design rules and test methods
  • Six Sigma Black Belt certified (or in process of becoming certified)

• Experience in helping resolve field issues associated with welding

• Knowledge of welding in designs from our competition

• Fundamental understanding of battery cell types (e.g. cylindrical pouch prismatic) basic pack construction and the purpose of cell interconnects and busbars.

• Understanding of battery safety protocols particularly regarding handling potential short circuits and thermal events during assembly.

General Skills

• 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
• 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

Even better you may have...

• 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

You may not check every box or your experience may look a little different from what weve outlined but if you think you can bring value to Ford Motor Company we encourage you to apply!

As an established global company we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe or keep you close to home Will your career be a deep dive into what you love or a series of new teams and new skills Will you be a leader a changemaker a technical expert a culture builderor all of the above No matter what you choose we offer a work life that works for you including:

• Immediate medical dental vision and prescription drug coverage

• Flexible family care days paid parental leave new parent ramp-up programs subsidized back-up child care and more

• Family building benefits including adoption and surrogacy expense reimbursement fertility treatments and more

• Vehicle discount program for employees and family members and management leases

• Tuition assistance

• Established and active employee resource groups

• Paid time off for individual and team community service

• A generous schedule of paid holidays including the week between Christmas and New Years Day

• Paid time off and the option to purchase additional vacation time.

This position is a leadership level 6.

For more information on salary and benefits click here: sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race religion color age sex national origin sexual orientation gender identity disability status or protected veteran the United States if you need a reasonable accommodation for the online application process due to a disability please call 1-.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week. #LI-Hybrid

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