This paper presents a novel approach for seam tracking usingultrasonics. An ultrasonic seam tracking system has been developed for roboticwelding which tracks a seam that curves freely on a two-dimensional surface. Theseam is detected by scanning the area ahead of the torch and monitoring theamplitude of the waves received after reflection from the workpiece surface.Scanning is accomplished by using two ultrasonic sensors (a transmitter and areceiver) mounted on a stepper motor such that the transmitter angle is the sameas the receiver angle. The motor is mounted on the end-effector just ahead ofthe welding torch and covers a ninety degree arc in front of the torch. If thereis no seam then the receiver receives most of the transmitted waves afterreflection, but if there is a seam then most of the transmitted waves aredispersed in directions other than that of the receiver. The system has beentested and is very robust in the harsh environments generated by the arc weldingprocess. The robustness of the system stems from using various schemes such astime windowing, a waveguide, air and metal shields, and an intelligent sensormanager. This ultrasonic system offers some distinct advantages over traditionalsystems using vision and other sensing techniques. It can be used to weld veryshiny surfaces, and is a very economical method in terms of cost as well ascomputational intensity. The system can be used to detect seams less than 0.5 mmwide and 0.5 mm deep.