In this paper, an attempt is made to determine input-output relationships of the cladding by flux cored arc welding process using regression analysis based on the a three factor, five level central composite experimental design with six centre points. After measuring bead width, depth of penetration and reinforcement; based on simple assumptions on the shape of bead geometry, other relevant bead geometry parameters are calculated. Several linear and curvilinear regression analyses are employed to establish the inputoutput relations and the best set of equations is then selected. Finally simulated annealing has been applied for parametric optimization of this welding technique.

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