242 Int. J. Productivity and Quality Management, Vol. 19, No. 2, 2016 Copyright © 2016 Inderscience Enterprises Ltd. Development of response – dilution maps for super duplex stainless steel claddings deposited by FCAW B. Senthilkumar* Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore – 641 049, India Email: bsk_senthilkumar@hotmail.com *Corresponding author T. Kannan SVS College of Engineering, Coimbatore – 642 109, India Email: kannan_kct@yahoo.com K.K. Arun Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore – 641 049, India Email: arunmyies@gmail.com Abstract: This paper aimed at developing the response – dilution maps using response surface methodology. The proposed map is vital to achieve desired composition, properties and weld bead dimensions in stainless steel claddings. Controlled heat input and percentage dilution will enable the matching of surfaced layer properties with intended alloy. The flux cored arc welding (FCAW) process was selected because of its smooth bead appearance, deposition rate, automation and positional capabilities. The relationship between the welding parameters and responses were expressed as mathematical models. The identified input parameters are welding voltage, wire feed rate, welding speed, nozzle to plate distance and welding gun angle. The models were validated statistically and experimentally. The proposed map explores the effect of interaction between the welding voltage and wire feed rate on the bead geometry and percentage dilution. The effect of interaction between welding voltage, wire feed rate and nozzle to plate distance on the responses reinforcement height, bead width and percentage dilution was studied using response dilution maps. Keywords: duplex; stainless; cladding; flux cored arc welding; FCAW; welding; simulation; automation; modelling. Reference to this paper should be made as follows: Senthilkumar, B., Kannan, T. and Arun, K.K. (2016) ‘Development of response – dilution maps for super duplex stainless steel claddings deposited by FCAW’, Int. J. Productivity and Quality Management, Vol. 19, No. 2, pp.242–257.