R&D Materials Science - Welding Engineering Lab Process Development & Qualification, Onsite

Sandia National Laboratories is the nation's premier science and engineering lab for national security and technology innovation, with teams of specialists focused on cutting-edge work in a broad array of areas. Some of the main reasons we love our jobs:

• Challenging work with amazing impact that contributes to security, peace, and freedom worldwide
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• Career advancement and enrichment opportunities
• Flexible work arrangements for many positions include 9/80 (work 80 hours every two weeks, with every other Friday off) and 4/10 (work 4 ten-hour days each week) compressed workweeks, part-time work, and telecommuting (a mix of onsite work and working from home)
• Generous vacation, strong medical and other benefits, competitive 401k, learning opportunities, relocation assistance and amenities aimed at creating a solid work/life balance*

World-changing technologies. Life-changing careers. Learn more about Sandia at: http://www.sandia.gov

*These benefits vary by job classification.

The Metallurgy and Welding Engineering team is seeking a motivated and technically strong R&D Staff Member to support and expand Weld Lab capabilities in process characterization, development, qualification, and mission-relevant welding support. This role will contribute to the advancement of laser welding processes and related laboratory capabilities in support of Sandia's critical component development and production-relevant activities.

The successful candidate will work on a variety of technically challenging efforts, including beam characterization, advanced weld process diagnostic tools, experimental planning, process development, qualification support, and customer/stakeholder engagement. This position will require strong analytical skills, sound engineering judgment, and the ability to independently execute technical work in a highly collaborative, mission-focused environment.

This role is well suited for a high-performing early career candidate with a background in materials science, mechanical engineering, welding engineering, or a related discipline who is ready to take on increasing technical responsibility and support the lab's growing portfolio of work.

This position will play an important role in supporting the Weld Lab's expanding technical scope and increasing demand for process development and qualification support. The ideal candidate will be comfortable operating in a dynamic environment, balancing multiple technical priorities, and helping establish repeatable, well-documented processes that support long-term mission needs.

On any given day, you will:

• Support and lead selected R&D process development and characterization activities within the Weld Lab, including efforts that require independent technical planning, experimentation, and execution.
• Develop and execute designs of experiments (DOE) for laser welding and related process characterization efforts, including evaluation of variables such as power, beam intensity, focal position, focal length, travel speed, and other relevant parameters.
• Support beam characterization and process capability studies for existing and new laser welding tools, including wobble laser systems and new IPG laser platforms.
• Work with customers, stakeholders, and production partners to define technical needs, align priorities, and support planning for funded development work.
• Contribute to process qualification, process validation, and production-relevant welding support, including collaboration with KCNSC and other NSE partners.
• Assist in the development of process documentation, technical reports, procedures, presentations, and other deliverables that capture knowledge and support long-term lab capability.
• Support troubleshooting, process optimization, and improvement of welding processes, tooling, and system performance.
• Collaborate with technologists, interns, and other staff to strengthen team bench depth, transfer knowledge, and maintain sustainable lab operations.
• Evaluate and present technical data clearly through graphs, figures, summaries, and oral/written communication.
• Contribute to strategic planning for Weld Lab capability growth and help identify technical gaps, opportunities, and future needs.

Due to the nature of the work, the selected applicant must be able to work onsite.

$102,400 - $199,700

*Salary range is estimated, and actual salary will be determined after consideration of the selected candidate's experience and qualifications, and application of any approved geographic salary differential.

• Bachelor's degree in a relevant discipline and five (5) years of directly relevant experience, or an equivalent combination of directly relevant education and engineering or scientific experience that demonstrates the knowledge, skills, and ability to perform independent research and development.
• Ability to obtain a DOE Q clearance
  

The ideal R&D Materials Science candidate for Sandia National Laboratories will, in addition, possess the following:

• Master's degree in Welding Engineering, Materials Science, Mechanical Engineering, or a closely related field.
• Familiarity with welding, materials processing, or related manufacturing processes.

Also, for this posting we are seeking individuals with the following experience:

• Demonstrated experience in process development, experimental design, technical analysis, or applied R&D in a laboratory, engineering, or manufacturing environment, in relationship to laser welding.
• Ability to independently develop technical work plans and carry them through to completion with minimal oversight.
• Strong written and verbal communication skills, including the ability to work effectively with customers, stakeholders, and technical partners.
• Experience with engineering or data analysis tools such as SolidWorks, AutoCAD, MATLAB, Excel, or similar software.
• Demonstrated experience designing bespoke laser welding fixturing for R&D test specimens and prototypes.
• Ability to work collaboratively in a team environment while also taking ownership of assigned technical efforts.
• Direct engagement with KCNSC and/or other NSE production partners.
• Experience supporting process qualification, process validation, or production development efforts.
• Knowledge of metallurgy, weldability, and materials characterization.
• Experience with advanced laser welding process characterization tools including beam profilers, beam analysis software, high-speed videography, power/energy meters, laser photodiodes, interferometers, etc.
• Familiarity with laser welding systems, wobble beam welding, or precision joining processes.
• Experience developing and executing DOE-based studies for welding process window characterization.
• Demonstrated ability to interface effectively with customers and stakeholders to define scope, identify needs, and support execution.
• Experience supporting mission-focused or high-consequence component development.
• Ability to mentor technologists, interns, or early-career staff in technical work and laboratory practices.
  

The Metallurgy and Welding Engineering Department is the principal organization for metallurgy research and development throughout Sandia. Our expertise covers a broad range of experimental and predictive capabilities that apply fundamental process as well as applied physical and mechanical metallurgy principles. Specific technical areas include laser welding, failure analysis, mechanical testing, physical metallurgy, and others. Our scientific focus is on materials structures, properties, performance and reliability. We support an extensive variety of national security programs and we are highly engaged in providing collaborative, innovative materials science and systems-based engineering solutions.

This posting will be open for application submissions for a minimum of three (3) calendar days, including the 'posting date'. Sandia reserves the right to extend the posting date at any time.

Sandia is required by DOE to conduct a pre-employment drug test and background review that includes checks of personal references, credit, law enforcement records, and employment/education verifications. Applicants for employment need to be able to obtain and maintain a DOE Q-level security clearance, which requires U.S. citizenship. If you hold more than one citizenship (i.e., of the U.S. and another country), your ability to obtain a security clearance may be impacted.

Applicants offered employment with Sandia are subject to a federal background investigation to meet the requirements for access to classified information or matter if the duties of the position require a DOE security clearance. Substance abuse or illegal drug use, falsification of information, criminal activity, serious misconduct or other indicators of untrustworthiness can cause a clearance to be denied or terminated by DOE, resulting in the inability to perform the duties assigned and subsequent termination of employment.

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, or veteran status and any other protected class under state or federal law.

If you have a Medical Portable Electronic Device (MedPED), such as a pacemaker, defibrillator, drug-releasing pump, hearing aids, or diagnostic equipment and other equipment for measuring, monitoring, and recording body functions such as heartbeat and brain waves, if employed by Sandia National Laboratories you may be required to comply with NNSA security requirements for MedPEDs.

If you have a MedPED and you are selected for an on-site interview at Sandia National Laboratories, there may be additional steps necessary to ensure compliance with NNSA security requirements prior to the interview date.