The paper describes a theoretical study conducted to investigate effect of the process parameters in the cladding work
performed using a kind of fusion welding process i.e. flux cored arc welding (FCAW). It involves a statistical empirical model
developed on the basis of regression analysis to predict the weld bead geometry for the given set of process parameters, in the
form of mathematical correlations. The formulation is made with an inclusion of significance/weightage analysis for the
parameters like penetration, reinforcement, weld bead width and percentage dilution to limit the mathematical labour for the
second-order polynomial equation. Also, effect of each variable is traced separately to know the corresponding influence on the
behaviour of rest of the process parameters thereby on the weld bead geometry.
