Abstract: The appearance of defects during the manufacture of tanker trucks via arc-welding is a significant problem in the industry. A reliable low-cost and non-destructive on-line method could aid the discovery of solutions to overcome productivity problems. Plasma optical spectroscopy was employed in this study to correlate the presence of several elemental emission lines with certain quality-related events, such as the appearance of porosities. Results obtained through field trials and also during in-line production show that the convenient processing of acquired process signals facilitates not only the detection of defects, but also the identification of their causes. Output monitoring signals have been compared with X-ray inspections of the seam welds performed. It has been demonstrated that the spectroscopic monitoring variables obtained are good indicators for evaluating contamination in the process and therefore the occurrence of welding defects.

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