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Friction Stir Weld (FSW) Engineer

Orrvilon Inc gas launch a new product-line based on METAMICÒ HT aluminum boron carbide metal matrix composite technology. This material was developed specifically for high temperature “dry” storage of spent nuclear fuel for various clients world wide to support the nuclear power generation industry.


One of the critical operation in the fabrication of the METAMICÒ HT basket component is the joining of the separate panels using friction stir welding  (FSW) technology. Technical capability has been demonstrated in a production environment retro fitting a conventional Giddings & Lewis horizontal CNC mill. This system has cumbersome support tooling, limited “Y” axis travel, and is 1978 technology, which is a “bottle neck in the METAMICÒ HT Basket production.


To resolve the FSW joining technology inadequate production rate – Orrvilon has procured a $4M state-of-the-art FSW machine specifically designed for the METAMICÒ HT Baskets which is being manufactured by Novatech Engineering capable of producing 12 baskets per month capacity. This project is considered “core” business to Holtec International and requires a dedicate FSW Engineer to be involved at the ground level to assure the company manufactured high quality FSW in a single pass and meets the designed production rate in a total automatic FSW cycle to eliminate operator errors associated with manual operation. 


FSW Engineer Job Responsibilities:

  • Equipment manufacturing phase – the engineer shall interface with Nova-tech engineering staff o learn all aspects of the equipments capabilities and tack the manufacturing schedule to assure compliance to the purchase and delivery schedule.
  • Audit all sub vendors for the Holtec deliverables to support the FSW machine such as turntable, fixtures, basket up-ender, installation of the foundation, electrical and other utilities required to operate the FSW center.
  • The engineer shall be proficient in the operation of the soft ware system so that all critical characteristics to assure high quality FSW (RPM, temperature, pressure, side load, etc.) have set limits to monitor the entire weld process. These critical characteristics shall have specific ranges, alarms when a parameter is out of range, and certify each weld for each client’s basket.
  • The engineer shall develop the optimum FSW tool design and FSW tool composition to reduce tool cost while maintaining welding quality and meet our production rates.
  • The engineer shall monitor the delivery of all FSW components and sub-contactors to adhere to this equipment delivery schedule.
  • The engineer shall work with corporate weld engineer to approve the FSW operators using PQR test plates that are mfg to a specific weld procedure to assure compliance to all NDT and destructive testing specifications.
  • Support the development of weld dissimilar materials to support advance basket designs.

Company Expectations: 

               Orrvilon Inc is looking for the type of employee that is willing to take total ownership of this critical new joining technology. This includes interfacing with all vendors, the equipment manufacturer, reporting delivery status to the Holtec Corporate office, and must importantly work with the shop floor personnel, engineers, and management at Orrvilon, Inc.


The FSW Engineer must have creativity, drive, and perseverance to resolve the problems associated with leading edge joining technology to meet the next-generation designs that make Holtec International and all of its division best-in-class for the spent fuel storage industry.  

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