By varying simultaneously six welding parameters, viz., current, voltage, polarity, electrode extension, flux basicity and travel speed within selected variation intervals in SAW process, an attempt was made to identify the parameters which mainly affect the mean levels of Mn and Cr transfer, penetration, bead width and reinforcement of weld deposit and the parameters which mainly affect the
... [Show full abstract] variabilities of these response characteristics. Weld polarity turned out to be the major parameter affecting the mean level of Mn transfer. On the other hand, none of the six welding parameters appear to have any real effect on the mean levels of Cr transfer. Variability of weld reinforcement reduced significantly at reverse polarity (electrode positive), higher travel speed and higher arc voltage. Use of high basicity flux reduced the variability of weld bead width and penetration.