An independent in-process quality monitoring (IPQM) system was designed as part of the procedure development to comply with products quality assurance requirements.

A review of the current in process data monitoring approaches was carried out and the most suitable manner to monitor the LFW process was defined. This was followed by the design and build of a test system that focused on high speed monitoring, forces and displacements and other key process factors. The capability of this IPQM system was proven using normal and intentionally off-normal weld samples.

The output of this system, a weld report, offers evidence to empower the LFW process engineer in his decision making role such as weld qualification, statistical process control and quality assurance. This monitoring system project should be transferable to other LFW machines in the future.