Weld joint penetration control is a basic research topic in the welding research community. The authors propose using an innovative plasma arc welding process referred to as the quasi-keyhole process to achieve less application-dependent weld joint penetration sensing and control. To control the quasi-keyhole process, the peak current and keyhole sustaining current are selected as the control variables to maintain the keyhole establishment and sustaining periods at desired values. The dynamic quasi-keyhole process is approximated by a linear model with interval parameters. A control algorithm has been developed for the multivariable interval quasi-keyhole process based on a predictive control algorithm for interval SISO models. Experiments have been conducted to test the effectiveness of the control system developed. (c) 2007 Elsevier Ltd. All rights reserved.