From precise welds in tight spaces to complex shapes in large machinery, our welders around the world lay down some of Caterpillar’s most challenging welds. Let’s meet some of our global fabrication team members who are proud of the difficult welds they are known for.
Aaron & Jeff, East Peoria, Illinois, United States
In East Peoria, the most challenging weld in the facility is on the Cat® D11 Dozer. Using a special welding process called HyperFill®, the D11 “butt weld” requires two fabricators to work simultaneously to achieve the perfect weld. Aaron and Jeff are two of the three operators in the facility who are certified to perform this weld.
Aaron and Jeff shared that being members of the small but mighty team who can complete this job on such an iconic product is a point of pride. Proof of their dedication to quality is that 99% of their welds pass an ultrasonic weld inspection. This inspection scans for sub-surface defects such as lack of fusion, penetration, porosity, or cracks and can detect any contamination to the weld.
Anth, Peterlee, England
In Peterlee, the most challenging weld occurs on the front chassis of the articulated trucks. Anth expressed that the weld has a small landing edge which requires extreme precision as there is not much room to work with.
Anth shared that this weld and others are satisfying to him because “you are 100% in control of your own quality.” He is proud to produce these tough welds and enjoys how his role allows for continuous learning.
Kasemsuk, Rayong, Thailand
Sukkasem shared that welding in general comes with its own set of challenges, but that is what makes the role engaging and enjoyable. He emphasized that quality and safety are always top of mind.
Sukkasem has dreamed of being a welder for his whole life. He shared, “I have been passionate about it for as long as I can remember. Even after more than 12 years in the field, I still love what I do. I take great pride in seeing my work come to life – it is incredibly satisfying to know that my skills contribute to something bigger.”
Jesse, South Milwaukee, Wisconsin, United States
In South Milwaukee, Jesse uses ultrasonic testing to inspect multi-pass weld joints to ensure welds are up to quality standards. When the test reveals a defect, he uses an air arc to gouge the weld material until he can locate the defect. Jesse fully removes defects and successfully refills the welding joint before inspecting it again. Removing and refilling a weld after the first attempt is an incredibly challenging task, and South Milwaukee is fortunate to have a skilled welder like Jesse on their team who is up for the job.
Jesse is dedicated to teaching the next generation of Caterpillar welders. He shared, “I find personal fulfillment in being able to help our younger team members learn and develop their skills.”
A Babu, Thiruvallur, India
In Thiruvallur, A Babu has extensive knowledge of a variety of welding techniques and is always searching to learn more. A Babu is actively learning two advanced welding techniques and will join a team of only four others in Thiruvallur who are certified to perform these complicated welds.
When asked about what makes his job satisfying, A Babu responded, “What I love most about welding is the thrill of working with different techniques. The sense of accomplishment from mastering these techniques and contributing to significant projects makes my work incredibly rewarding. I enjoy the continuous learning and the opportunity to mentor new team members. This makes my job not just a profession, but a passion.”
Jeremy, Decatur, Illinois, United States
According to fabrication specialist Jeremy, the most challenging weld in Decatur takes place on the Cat® 793F Large Mining Truck. The center tube is large, and the shape adds an extra challenge to this operation. Jeremy went through extensive training and testing before working as a welder on the massive machines in Decatur. Each new welder must go through the weld school on Decatur’s campus, which is an eight-week course consisting of sixteen tests covering mig, flux core, and tig toe dressing. Decatur weld school students are held to the highest standards and must meet strict criteria before moving to the shop floor.
Jeremy shared that even when working on difficult welds, he enjoys what he does immensely. He loves working with his hands and is always striving to improve and learn new techniques.
Riswan, Batam, Indonesia
In Batam, Riswan shared, “welding is more than just joining metal – it is an intricate skill that requires precision, patience, and a deep understanding of the process.” Riswan's top priority with each weld he performs is quality.
Riswan dreamed of being a welder for many years, working as an assistant and grinder before being promoted to welder. He finds great satisfaction in his role, and the most rewarding part of his job is seeing the results of his efforts pay off. Welding is not a job to Riswan, but a craft that he takes pride in mastering.
Chad, Denison, Texas, United States
In Denison, Chad finds the most challenging welds are done on fully assembled machines. Navigating around assembled parts can be difficult because it requires high adaptability, but that is what makes the role exciting for Chad.
When asked why he loves his work, Chad shared that seeing the finished product is the coolest part of his job. Being a part of a skilled team that helps to get the products out the door is something he takes pride in.
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Curious about what a typical day for our welders looks like? Watch this short video to find out!
Interested in joining Caterpillar’s fabrication team? Explore open welding positions here.
