The effect of flux-cored arc welding (FCAW) process parameters on the quality of the super duplex stainless steel (SDSS) claddings can be studied using Taguchi L9 design of experiments. In this experimental investigation, deposits were made with 30 % bead overlap. Establishing the optimum combination of process parameters is required to ensure better bead geometry and desired properties. The above objectives can be achieved by identifying the significant input process parameters as input to the mathematical models like welding voltage (X 1 ), wire feed rate (X 2 ), welding speed (X 3 ), and nozzle-to-plate distance (X 4 ). The identified responses governing the bead geometry are bead width (W) and height of the reinforcement (H). The mathematical models were constructed using the data collected from the experiments based on Taguchi L9 orthogonal array. Then, the responses were optimized using non-traditional nature-inspired technique like genetic algorithm (GA).

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The effect of Gas Metal Arc Welding process parameters on the bead geometry of stainless steel (SS) claddings can be studied using statistical Taguchi L9 design of experimental model. In this study deposits were made with continuously varying weld bead overlaps of 0 – 100%. Cladding is proposed to impart corrosion inhibition properties to the low carbon structural steel plate. Selection of welding process parameters affects the arc stability, heat input deposition rate and quality of the surfaced layer represented by the percentage dilution. Minimization of heat input leads the reduced deposition rate and increased occurrences of weld bead defects like porosity, lack of fusion and cracking. In this context, it is important to identify the extent of influence exerted by the controlled welding parameters on the bead geometry. The reinforcement dimensions play an important role in the cladding process. Stainless steel claddings are deposited by automated Gas Metal Arc Welding (GMAW) process by using Taguchi L9 design of experiment. The selected input variables are Welding voltage (WV), Wire feed rate (WFR), Welding speed (WS) and NTPD. The responses identified governing the bead geometry like bead width (w) and height of the reinforcement (h) in different bead overlaps like 0%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%. The paper also explores the variation in the bead geometry at different levels of overlap percentages including hardness evaluation.