Senior Welding Engineer

Description

As a Weld Engineer at Impulse you will help develop, qualify and optimize welding designs and processes with both laser beam, gas tungsten arc welding, friction stir welding, and orbital tube welding.

This role will integral to performing weld developments on Helios' main structural tank, Deneb’s thrust chamber and preburner assemblies, and valve components across all of our vehicles.

The welding engineer in this role will interface daily with design and manufacturing engineers to make welding judgment calls and improvements and will enforce standardized practices and procedures on multiple welded assemblies.

Helios is Impulse's new vehicle, a 3rd stage / kick stage. Launching in 2026, it is designed to take satellites & payloads to GEO for 1 / 3rd of today's current cost.

Deneb is Impulse’s 15k lb thrust lox methane staged combustion engine.

Responsibilities

• Develop, optimize, and qualify weld processes and parameters for multiple welding processes including but not limited to : laser beam welding, friction stir welding, gas tungsten arc welding, orbital tube welding.
• Work closely with design, tooling, automation, and development engineers to improve welded designs for manufacturing
• Develop and implement improved process control where possible using test and NDE results as feedback loop
• Support production operations on full scale welded assemblies, providing direction to manufacturing engineers and welders on correct techniques in a fast paced manufacturing environment
• Support on-site manufacturing and development of Helios tank, Deneb engine weldments, and Mira components.
• Set up welding qualification test campaigns and interpret mechanical testing and NDE results
• Work closely with NDE personnel to interpret weld quality on development and flight hardware in addition to developing and implementing innovative state-of-the-art NDE techniques
• Set up automated welding solutions in an effort to drive process consistency
• Scope out new welding technologies that may be employed to improve rate / quality / efficiency
• Support design, manufacturing, and materials engineering with root cause analysis

Minimum Qualifications

• Bachelor’s degree in an engineering discipline
• 5+ years of experience with hands-on fabrication, manufacturing, or testing experience of welded assemblies

Preferred Skills and Experience

• Master’s degree in welding engineering or related technical program
• 5+ years' of demonstrated hands-on welding experience of aluminum, nickel-based, stainless steel, titanium, and copper alloys.
• 5+ years' of demonstrated experience with brazing, joining, and metallographic interpretation
• Fundamental understanding of welding processes including, but not limited to, laser beam, friction stir, gas tungsten arc, gas metal arc, electron beam, plasma arc, and resistance welding
• Robot programming experience for automated welding solutions
• Tooling design experience for welded assemblies to reduce part distortion and improve part consistency
• Understanding of weld strength testing methodologies, standards, and data acquisition systems used to make informed welding decisions (ASTM E8, E399, E740, ISO 15653, AWS D17.

X, AWS C7.X, thermos-couples, strain gages, etc.)

• Experience with root cause analysis and corrective actions including, but not limited to, optical and SEM fractography / metallography, hardness, chemical analysis, and mechanical testing
• Self-motivated, driven and high attention to detail
• Strong ability to multi-task and communicate status and results with broad spectrum of internal and external departments

Additional Information :

Compensation bands are determined by role, level, location, and alignment with market data. Individual level and base pay is determined on a case-by-case basis and may vary based on job-related skills, education, experience, technical capabilities and internal equity.

In addition to base salary, for full-time hires, you may also be eligible for long-term incentives, in the form of stock options , and access to medical, vision & dental coverage as well as access to a 401(k) retirement plan .

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.

S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.

S. Department of State. Learn more about the ITAR here .

Impulse Space is an Equal Opportunity Employer; employment with Impulse Space is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin / ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.

Impulse Space, the in-space transportation company founded by Tom Mueller, is opening access beyond Low Earth Orbit (LEO) with its fleet of in-space transportation vehicles.

The high-energy Helios vehicle unlocks orbits beyond LEO with its powerful Deneb engine, dropping off payloads in MEO, GEO, heliocentric, lunar, and other planetary orbits.

The flight-proven Mira vehicle uses a nontoxic, high-impulse chemical propulsion system to offer orbital transport, constellation deployment, and precision reentry services to customers throughout LEO.

Led by a team that delivered the most reliable rockets in history, Impulse provides economical and efficient in-space transportation by reliably and rapidly getting customers where they want to go.