QA for Welding Cells: Coupons, Coupons, Coupons

Every robotic weld program is only as good as its validation. The fastest way to verify quality — before production begins — is still the humble weld coupon.

1. Why Coupons Matter

Coupons simulate real parts with identical material, thickness, and joint geometry. They validate parameters, ensure penetration, and confirm positional accuracy before the first production weld.

2. Automating QA Routines

• Barcode-tag coupons to link results to program versions.
• Log weld voltage, current, and travel speed automatically via robot I/O.
• Store NDT (non-destructive test) results in the MES for full traceability.

3. Continuous Verification

Schedule requalification after any change in tooling, gas, or wire batch. Integrate SPC analysis to track variation in bead width and penetration over time.

Example

A contract manufacturer built automated coupon test stations. Each robot cell validates one weld every 50 cycles, storing results in a unified quality database.

Related Articles

• Heat, Spatter, and Safety: What to Engineer Upfront
• Seam Tracking with Vision and Through-Arc
• Offline Programming: From CAD to Weld Path

Conclusion

Coupons keep robotic welding honest. Combined with automated QA and digital traceability, they ensure weld integrity without sacrificing uptime.