Senior Electron Beam Welding Engineer

Job Summary 

Kairos Power is seeking a highly motivated Senior Electron Beam Welding Engineer that will be responsible for in-house electron beam welding (EBW) capability development and technology maturation. In this role, you will work on the Welding Development team to assist in the advancement and implementation of welding and manufacturing capabilities. The candidate will partner with design, testing, materials, modeling & simulation, and reliability engineers to develop weld joint design, weld techniques, weld specifications, and inspection methods needed for welded KP-FHR and test platform assemblies.

Responsibilities

Procedure Development & Qualification

• 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.
• Develop and execute weld qualification plans, including test coupons and validation trials, in coordination with quality and materials teams
• Anticipate future welding needs by aligning EBW procedures and qualification strategies with evolving product designs, manufacturing processes, and regulatory demands.

Quality Assurance & Process Optimization

• Oversee and review EBW inspections to verify compliance with design specifications and applicable quality standards.
• Analyze weld test data to identify trends, determine root causes of defects, and implement corrective actions to enhance welding performance and reliability.
• Lead continuous improvement initiatives to optimize EBW processes, increase efficiency, reduce cost, and maintain high-quality output.

Collaboration & Training

• Partner with design engineers, production teams, and key stakeholders to integrate EBW processes into the manufacturing workflow effectively.
• Provide hands-on training and mentorship to welding technicians and operators on EBW techniques, safety protocols, and industry best practices.

Technical Documentation & Reporting

• Develop and maintain comprehensive technical documentation, including process instructions, work procedures, and detailed reports.
• Ensure accurate recordkeeping of EBW procedures, inspection results, and quality control data to support traceability and continuous improvement.

Equipment Ownership & Maintenance

• Ensure performance, reliability, and availability of EBW systems, including high-vacuum chambers, beam control units, and power supplies.
• Monitor and calibrate critical parameters (e.g., beam alignment, focus, power output, vacuum integrity) to maintain process consistency and compliance with specifications.
• Lead maintenance and upgrade initiatives, including preventive planning, troubleshooting, vendor coordination, and system improvements to enhance automation and long-term equipment reliability.

Other Duties as Assigned

Qualifications

• Bachelor’s degree or higher in Welding Engineering, Materials Science, Mechanical Engineering, or a related technical field
• Minimum 5 years of welding engineering experience, with substantial hands-on experience in EBW required
• Experience with weld inspection methods, including both destructive testing and non-destructive examination (NDE) techniques
• Hands-on experience working with austenitic stainless steels, carbon steels, piping systems, and pressure vessels
• Experience leading cross-functional projects or mentoring junior engineers and technicians is preferred.
• Experience with manual and CNC machining operations is preferred

Knowledge, Skills & Abilities

• Strong knowledge of EBW processes, high-vacuum systems, and high-voltage equipment operation
• Proficient in reading and interpreting complex engineering and assembly drawings, including weld symbols and geometric dimensioning & tolerancing (GD&T)
• Familiarity with ASME Boiler and Pressure Vessel Code and AWS structural welding standards
• Skilled in using CAD software such as SolidWorks for part modeling and drawing generation
• Proficient with computers and digital tools used in technical documentation, data analysis, and process development
• Familiarity with the calibration, preventive maintenance, and troubleshooting of EBW systems and associated instrumentation.
• Strong problem-solving skills and ability to drive continuous improvement through data-driven analysis and collaboration
• Proven ability to manage multiple priorities in a fast-paced, agile manufacturing or development environment
• Excellent verbal and written communication skills; able to collaborate effectively across engineering, production, and quality teams
• Ability to collect, manage, and transfer technical knowledge across teams or documentation systems
• Committed to fostering a safe, inclusive, and high-performing workplace
• Ability to work with highly collaborative team.
• Ability to solve problems quickly and efficiently.
• Prioritizes and ensures safety of oneself and others.
• Ability to seek different and novel ways to create efficiencies when working on problems, challenges and issues.

Physical Demands

• Ascending or descending ladders, stairs, scaffolding, ramps, scissor lifts, articulated boom lifts and the like
• Setting up and transferring temporary structures (e.g. scaffolding, ladders)
• Moving self in different positions to accomplish tasks in various environments including tight and confined spaces
• Remaining in a stationary position, often standing, or sitting for prolonged periods
• Moving about to accomplish tasks or moving from one worksite to another
• Adjusting, moving, transporting, installing, positioning, or removing objects up to 50 pounds in all directions
• Communicating with others to exchange information
• Operating motor vehicles, heavy equipment or machinery
• Use hand tools
• Repetitive assembly operations of manufacturing test fixtures and test setups in collaboration with engineering and manufacturing teams 

Environmental Conditions

• Low temperatures
• High temperatures
• Outdoor environment or elements such as precipitation and wind 
• Noisy environments
• Small and/or enclosed spaces
• Odors or fumes from chemicals or chemical reactions
• Elevated heights
• Accessing the accuracy, neatness and thoroughness of the work assigned
• High-concentration, demanding and fast-paced
• General office environment
• Manufacturing/Industrial Environment

Safety and PPE

• Reading and interpreting hazardous warning signs
• Wearing proper PPE, to include face mask, face shields, gloves, safety shoes, etc.
• Reporting issues with equipment or unsafe conditions

Travel

• Some travel may be required (up to 20%) to other Kairos Power offices or external suppliers

Additional Requirements

• Occasionally requires overtime
• Occasionally requires working weekends 
• Occasionally requires schedule flexibility
• Occasionally requires non-standard work-week hours 
• Occasionally requires extended hours to support launch and critical project timelines

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