The arc welding process is so complex that the classical modeling method cannot obtain the model effectively. However, the model of the arc welding process is necessary for the intelligent control of the process. Therefore, the modeling has been the interest of many researchers. Recently, more and more researchers are attempting to obtain the model of the process by means of intelligent methods, such as the neural network method, the fuzzy set method, and so on. All these methods concentrate on simulating the intelligent behavior of human beings, namely using human experience. Many applications of these methods have proved their effectiveness under certain conditions. However, their limits are obvious and further research is needed. This paper proposes a method of rough set based knowledge modeling for the aluminum alloy pulsed gas tungsten arc welding (GTAW) process. Owing to the ability of dealing with knowledge (experience) of the rough set theory, the method can obtain the knowledge model of the aluminum alloy pulsed GTAW process. The model obtained is easily understood and revised. Experiment results indicate that the method is effective. The method can be regarded as the basis of the intelligent control of the welding process.

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