Current industrial robotic welding systems cannot achieve automated solutions for multi-layer multi-pass welding of complex joints due to the presence of non-uniform and irregular welding groove geometries.This paper presents an adaptive pass planning approach for robotic welding of such complex joints.The welding groove is first segmented considering both the variation in groove dimension and the reachability of the robot welding torch.For each welding segment,the welding passes are planned to be in accordance with welding practices,viz.,keeping the same number of welding passes in each layer while maintaining consistent welding parameters.An adaptive pass adjustment scheme is developed to address the discrepancies between the simulated results and the actual welding deposition after finishing a few layers of welding.Corresponding robot paths are generated and optimized to ensure minimum joint movement subject to three constraints,viz.,reachability,collision-free and singularity avoidance.The proposed approach has been simulated with the arc welding of a Y-type joint found typically in offshore structures.