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Flux Core Arc Welding (FCAW)is a popular choice for metal fabrication. Correct welding parameter and bead geometry are required before a robot can perform quality welding. An experiment was conducted to study the correlation between weld bead geometry and welding parameter for bead-on-plate in 1G position, and subsequently to develop a tool that can support the input requirement of the robot without resorting to unproductive trial and error. Coupons of quality weld deposit were produced experimentally by FCAW process and the bead geometry is measured and tabulated. The correlation of Heat Input and weld bead geometry is best represented by their trend-line equations. Incorporating these equations into a calculator format, the weld bead geometry and welding parameters can be predicted to produce a wide range of bead geometry. The deviation between predicted data and experimental measurement on actual welding is less than 1mm, while the Mean Absolute Deviation is less than 0.6mm.

Prediction of Flux Core Arc Welding (FCAW) Bead Geometry and Welding Parameters for 1G Position