The Experts below are selected from a list of 2319 Experts worldwide ranked by ideXlab platform

D. Katherasan - One of the best experts on this subject based on the ideXlab platform.

  • Simulation and parameter optimization of flux cored Arc Welding using artificial neural network and particle swarm optimization algorithm
    Journal of Intelligent Manufacturing, 2014
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya
    Abstract:

    Flux cored Arc Welding (FCAW) process is a fusion Welding process in which the Welding electrode is a tubular wire that is continuously fed to the weld area. It is widely used in industries and shipyards for Welding heavy plates. Welding input parameters play a very significant role in determining the quality of a weld joint. This paper addresses the simulation of weld bead geometry in FCAW process using artificial neural networks (ANN) and optimization of process parameters using particle swarm optimization (PSO) algorithm. The input process variables considered here include wire feed rate (F); voltage (V); Welding speed (S) and torch Angle (A) each having 5 levels. The process output characteristics are weld bead width, reinforcement and depth of penetration. As per the statistical design of experiments by Taguchi L_25 orthogonal array, bead on plate weldments were made. The experimental results were fed to the ANN algorithm for establishing a relationship between the input and output parameters. The results were then embedded into the PSO algorithm which optimizes the process parameters subjected to the objectives. In this study the objectives considered are maximization of depth of penetration, minimization of bead width and minimization of reinforcement.

  • Modeling and optimization of flux cored Arc Welding by genetic algorithm and simulated annealing algorithm
    Multidiscipline Modeling in Materials and Structures, 2013
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya, A. Noorul Haq
    Abstract:

    Purpose – The purpose of this study is to optimize the process parameters (wire feed rate (F), voltage (V), Welding speed (S) and torch angle (A)) in order to obtain the optimum bead geometry (bead width (W), reinforcement (R) and depth of penetration (P)), considering the ranges of the process parameters using evolutionary algorithms, namely genetic algorithm (GA) and simulated annealing (SA) algorithm. Design/methodology/approach – The modeling of Welding parameters in flux cored Arc Welding process using a set of experimental data and regression analysis, and optimization using GA and SA algorithm. Findings – The adequate mathematical model was developed. The multiple objectives were optimized satisfactorily by the GA and SA algorithms. The feasible solution results are very closer to the optimized results and the percentage error was found to be negligibly small. Originality/value – The optimal Welding parameters were identified in order to increase the productivity. The Welding input parameters effec...

  • Process Parameter Optimization of AISI 316L(N) Weld Joints Produced using Flux-Cored Arc Welding Process
    Transactions of the Indian Institute of Metals, 2013
    Co-Authors: D. Katherasan, Sameer Srivastava, P. Sathiya
    Abstract:

    Bead on plate welds were carried out on AISI 316L(N) austenitic stainless steel using flux cored Arc Welding process. The bead on plates weld was conducted as per L_25 orthogonal array with statistical design of experiment technique. In this paper, the Welding parameters will be optimized based on the weld bead geometry such as depth of penetration, bead width and weld reinforcement. Grey relational analysis and desirability approach are used to optimize the input parameters like wire feed rate, voltage, travel speed and torch angle while considering the multiple output variables simultaneously. Confirmation experiment has also been conducted to validate the optimized parameters.

  • Shielding gas effects on flux cored Arc Welding of AISI 316L (N) austenitic stainless steel joints
    Materials & Design, 2013
    Co-Authors: D. Katherasan, P. Sathiya, A. Raja
    Abstract:

    Abstract This paper deals with the flux cored Arc Welding (FCAW) of AISI 316L (N) austenitic stainless steel with 1.2 mm diameter of flux cored 316LT filler wire. The Welding was carried out with different shielding gas mixtures like 100% Ar, 95% Ar + 05% CO 2 , 90% Ar + 10% CO 2 , 80% Ar + 20% CO 2 , 75% Ar + 23% CO 2  + 2% O 2 and 70% Ar + 25% CO 2  + 5% O 2 and 100% CO 2 . The main aim of the work is to study the effect of various shielding gas mixtures on mechanical properties and metallurgical characters. The microstructures and ferrite content of the welds were analyzed. The mechanical characteristics such as impact test, microhardness and ductility of welds were carried out. The fracture surface impact samples were analyzed through scanning electron microscope (SEM). The fracture surface revealed a ductile rupture at room temperature and ductile rupture with a few cleavages at lower temperatures occurred. The toughness and ferrite percentages of the welds were decreased for increase of the CO 2 in shielding gas mixtures.

  • Flux Cored Arc Welding Parameter Optimization Using Particle Swarm Optimization Algorithm
    Procedia Engineering, 2012
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya, A. Noorul Haq
    Abstract:

    Abstract Flux cored Arc Welding (FCAW) process is a fusion Welding process in which the Welding electrode is a tubular wire that is continuously fed to the weld area. It is widely used in industries and shipyards for Welding heavy plates. Welding input parameters play a very significant role in determining the quality of a weld joint. This paper addresses the modeling of Welding parameters in FCAW process using a set of experimental data and regression analysis, and optimization using Particle Swarm Optimization (PSO) Algorithm. The input process variables considered here include wire feed rate (F); voltage (V); Welding speed (S) and torch Angle (A) each having 5 levels. The process output characteristics are weld bead width, reinforcement and depth of penetration. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. In the next stage, the proposed model is embedded into PSO algorithm to optimize the FCAW process parameters. In this study the objectives considered are maximization of depth of penetration, minimization of bead width and minimization of reinforcement. A comparative study on the effectiveness of the two algorithms on the optimization of the weld bead geometry is done

Govindaraj Magudeeswaran - One of the best experts on this subject based on the ideXlab platform.

  • Metallurgical characteristics of armour steel welded joints used for combat vehicle construction
    Elsevier, 2018
    Co-Authors: Govindaraj Magudeeswaran, Venkatesh Balasubramanian, Madhusudhan G Reddy
    Abstract:

    Austenitic stainless steel (ASS) and High nickel steel (HNS) Welding consumables are being used for Welding Q&T steels, as they have higher solubility for hydrogen in austenitic phase, to avoid hydrogen induced cracking (HIC) but they are very expensive. In recent years, the developments of low hydrogen ferritic steel (LHF) consumables that contain no hygroscopic compounds are utilized for Welding Q&T steels. Heat affected zone (HAZ) softening is another critical issue during Welding of armour grade Q&T steels and it depends on the Welding process employed and the weld thermal cycle. In this investigation an attempt has been made to study the influence of Welding consumables and Welding processes on metallurgical characteristics of armour grade Q&T steel joints by various metallurgical characterization procedures. Shielded metal Arc Welding (SMAW) and flux cored Arc Welding (FCAW) processes were used for making welds using ASS, LHF and HNS Welding consumables. The joints fabricated by using LHF consumables offered lower degree of HAZ softening and there is no evidence of HIC in the joints fabricated using LHF consumables. Keywords: Armour grade Q&T steel, Heat affected zone softening, Shielded metal Arc Welding process, Flux cored Arc Welding process, Austenitic stainless steel, Low hydrogen ferritic steel, High nickel stee

  • Cold Cracking of Flux Cored Arc Welded Armour Grade High Strength Steel Weldments
    Journal of Materials Science & Technology, 2009
    Co-Authors: Govindaraj Magudeeswaran, Venkatesh Balasubramanian, G. Madhusudhan Reddy
    Abstract:

    In this investigation, an attempt has been made to study the in∞uence of Welding consumables on the factors that in∞uence cold cracking of armour grade quenched and tempered (Q&T) steel welds. Flux cored Arc Welding (FCAW) process were used making welds using austenitic stainless steel (ASS) and low hydrogen ferritic steel (LHF) consumables. The difiusible hydrogen levels in the weld metal of the ASS and LHF consumables were determined by mercury method. Residual stresses were evaluated using X-ray stress analyzer and implant test was carried out to study the cold cracking of the welds. Results indicate that ASS welds ofier a greater resistance to cold cracking of armour grade Q&T steel welds.

  • influences of flux cored Arc Welding consumables on dynamic fracture toughness j1d of armour grade q t steel joints
    Fatigue & Fracture of Engineering Materials & Structures, 2009
    Co-Authors: Govindaraj Magudeeswaran, Venkatesh Balasubramanian, Madhusudhan G Reddy, S. Sathyanarayanan, A. Moitra, S. Venugopal, G. Sasikala
    Abstract:

    Quenched and tempered (Q&T) steels are prone to hydrogen-induced cracking in the HAZ after Welding. Austenitic stainless steel (ASS) Welding consumables are traditionally used for Welding of high hardness Q&T steels as they have higher solubility for hydrogen. The use of stainless steel consumables for a non-stainless steel base metal is not economical. In recent years, the developments of low hydrogen ferritic steel (LHF) consumables that contain no hygroscopic compounds are utilized for Welding of Q&T steels The use of ASS and LHF consumables for armour grade Q&T steel will lead to formation of distinct microstructures in their respective welds. This microstructural heterogeneity will have a drastic influence in the dynamic fracture toughness of the armour grade Q&T steel welds. Hence, an attempt was made in this paper to study the influence of Flux-Cored Arc Welding consumables on dynamic fracture toughness (J 1d ) of armour grade Q&T steel joints. The Flux-Cored Arc Welding consumables have a significant effect on the dynamic fracture toughness of the armour grade Q&T steel welds. The joints fabricated using ASS Flux-Cored wires showed superior J 1d values than the joints fabricated using LHF consumables and the base metal.

  • Influences of flux‐cored Arc Welding consumables on dynamic fracture toughness (J1d) of armour grade Q&T steel joints
    Fatigue & Fracture of Engineering Materials & Structures, 2009
    Co-Authors: Govindaraj Magudeeswaran, Venkatesh Balasubramanian, S. Sathyanarayanan, G. Madhusudhan Reddy, A. Moitra, S. Venugopal, G. Sasikala
    Abstract:

    Quenched and tempered (Q&T) steels are prone to hydrogen-induced cracking in the HAZ after Welding. Austenitic stainless steel (ASS) Welding consumables are traditionally used for Welding of high hardness Q&T steels as they have higher solubility for hydrogen. The use of stainless steel consumables for a non-stainless steel base metal is not economical. In recent years, the developments of low hydrogen ferritic steel (LHF) consumables that contain no hygroscopic compounds are utilized for Welding of Q&T steels The use of ASS and LHF consumables for armour grade Q&T steel will lead to formation of distinct microstructures in their respective welds. This microstructural heterogeneity will have a drastic influence in the dynamic fracture toughness of the armour grade Q&T steel welds. Hence, an attempt was made in this paper to study the influence of Flux-Cored Arc Welding consumables on dynamic fracture toughness (J 1d ) of armour grade Q&T steel joints. The Flux-Cored Arc Welding consumables have a significant effect on the dynamic fracture toughness of the armour grade Q&T steel welds. The joints fabricated using ASS Flux-Cored wires showed superior J 1d values than the joints fabricated using LHF consumables and the base metal.

  • effect of Welding processes and consumables on high cycle fatigue life of high strength quenched and tempered steel joints
    Materials & Design, 2008
    Co-Authors: Govindaraj Magudeeswaran, Venkatesh Balasubramanian, Madhusudhan G Reddy
    Abstract:

    Austenitic stainless steel (ASS) Welding consumables are traditionally used for Welding quenched and tempered steels as they have higher solubility for hydrogen in austenitic phase. An attempt was made in this investigation to explore an alternate consumable to replace expensive ASS consumables. Austenitic stainless steel and low hydrogen ferritic steel were used to fabricate the joints by shielded metal Arc Welding and flux cored Arc Welding processes. The joints fabricated using low hydrogen ferritic steel consumables showed superior fatigue performance than the joints fabricated using ASS consumables.

P. Sathiya - One of the best experts on this subject based on the ideXlab platform.

  • Simulation and parameter optimization of flux cored Arc Welding using artificial neural network and particle swarm optimization algorithm
    Journal of Intelligent Manufacturing, 2014
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya
    Abstract:

    Flux cored Arc Welding (FCAW) process is a fusion Welding process in which the Welding electrode is a tubular wire that is continuously fed to the weld area. It is widely used in industries and shipyards for Welding heavy plates. Welding input parameters play a very significant role in determining the quality of a weld joint. This paper addresses the simulation of weld bead geometry in FCAW process using artificial neural networks (ANN) and optimization of process parameters using particle swarm optimization (PSO) algorithm. The input process variables considered here include wire feed rate (F); voltage (V); Welding speed (S) and torch Angle (A) each having 5 levels. The process output characteristics are weld bead width, reinforcement and depth of penetration. As per the statistical design of experiments by Taguchi L_25 orthogonal array, bead on plate weldments were made. The experimental results were fed to the ANN algorithm for establishing a relationship between the input and output parameters. The results were then embedded into the PSO algorithm which optimizes the process parameters subjected to the objectives. In this study the objectives considered are maximization of depth of penetration, minimization of bead width and minimization of reinforcement.

  • Modeling and optimization of flux cored Arc Welding by genetic algorithm and simulated annealing algorithm
    Multidiscipline Modeling in Materials and Structures, 2013
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya, A. Noorul Haq
    Abstract:

    Purpose – The purpose of this study is to optimize the process parameters (wire feed rate (F), voltage (V), Welding speed (S) and torch angle (A)) in order to obtain the optimum bead geometry (bead width (W), reinforcement (R) and depth of penetration (P)), considering the ranges of the process parameters using evolutionary algorithms, namely genetic algorithm (GA) and simulated annealing (SA) algorithm. Design/methodology/approach – The modeling of Welding parameters in flux cored Arc Welding process using a set of experimental data and regression analysis, and optimization using GA and SA algorithm. Findings – The adequate mathematical model was developed. The multiple objectives were optimized satisfactorily by the GA and SA algorithms. The feasible solution results are very closer to the optimized results and the percentage error was found to be negligibly small. Originality/value – The optimal Welding parameters were identified in order to increase the productivity. The Welding input parameters effec...

  • Process Parameter Optimization of AISI 316L(N) Weld Joints Produced using Flux-Cored Arc Welding Process
    Transactions of the Indian Institute of Metals, 2013
    Co-Authors: D. Katherasan, Sameer Srivastava, P. Sathiya
    Abstract:

    Bead on plate welds were carried out on AISI 316L(N) austenitic stainless steel using flux cored Arc Welding process. The bead on plates weld was conducted as per L_25 orthogonal array with statistical design of experiment technique. In this paper, the Welding parameters will be optimized based on the weld bead geometry such as depth of penetration, bead width and weld reinforcement. Grey relational analysis and desirability approach are used to optimize the input parameters like wire feed rate, voltage, travel speed and torch angle while considering the multiple output variables simultaneously. Confirmation experiment has also been conducted to validate the optimized parameters.

  • Shielding gas effects on flux cored Arc Welding of AISI 316L (N) austenitic stainless steel joints
    Materials & Design, 2013
    Co-Authors: D. Katherasan, P. Sathiya, A. Raja
    Abstract:

    Abstract This paper deals with the flux cored Arc Welding (FCAW) of AISI 316L (N) austenitic stainless steel with 1.2 mm diameter of flux cored 316LT filler wire. The Welding was carried out with different shielding gas mixtures like 100% Ar, 95% Ar + 05% CO 2 , 90% Ar + 10% CO 2 , 80% Ar + 20% CO 2 , 75% Ar + 23% CO 2  + 2% O 2 and 70% Ar + 25% CO 2  + 5% O 2 and 100% CO 2 . The main aim of the work is to study the effect of various shielding gas mixtures on mechanical properties and metallurgical characters. The microstructures and ferrite content of the welds were analyzed. The mechanical characteristics such as impact test, microhardness and ductility of welds were carried out. The fracture surface impact samples were analyzed through scanning electron microscope (SEM). The fracture surface revealed a ductile rupture at room temperature and ductile rupture with a few cleavages at lower temperatures occurred. The toughness and ferrite percentages of the welds were decreased for increase of the CO 2 in shielding gas mixtures.

  • Flux Cored Arc Welding Parameter Optimization Using Particle Swarm Optimization Algorithm
    Procedia Engineering, 2012
    Co-Authors: D. Katherasan, Jiju V. Elias, P. Sathiya, A. Noorul Haq
    Abstract:

    Abstract Flux cored Arc Welding (FCAW) process is a fusion Welding process in which the Welding electrode is a tubular wire that is continuously fed to the weld area. It is widely used in industries and shipyards for Welding heavy plates. Welding input parameters play a very significant role in determining the quality of a weld joint. This paper addresses the modeling of Welding parameters in FCAW process using a set of experimental data and regression analysis, and optimization using Particle Swarm Optimization (PSO) Algorithm. The input process variables considered here include wire feed rate (F); voltage (V); Welding speed (S) and torch Angle (A) each having 5 levels. The process output characteristics are weld bead width, reinforcement and depth of penetration. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. In the next stage, the proposed model is embedded into PSO algorithm to optimize the FCAW process parameters. In this study the objectives considered are maximization of depth of penetration, minimization of bead width and minimization of reinforcement. A comparative study on the effectiveness of the two algorithms on the optimization of the weld bead geometry is done

T. Kannan - One of the best experts on this subject based on the ideXlab platform.

  • optimization of flux cored Arc Welding process parameters by using genetic algorithm
    The International Journal of Advanced Manufacturing Technology, 2017
    Co-Authors: B Senthilkumar, T. Kannan, R Madesh
    Abstract:

    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).

  • Analysis of flux cored Arc Welding process parameters by hybrid taguchi approach
    World Journal of Engineering, 2014
    Co-Authors: P. Sreeraj, T. Kannan, Maji Subhasis
    Abstract:

    This paper presents calculation of the Welding process parameters for obtaining optimal weld bead geometry in Flux Cored Arc Welding (FCAW) process. Bead on plate Welding was carried as per L16 orthogonal array. In this paper weld bead geometry such as penetration, bead width, reinforcement and percentage of dilution of IS 2062 structural steel plates investigated. Two hybrid techniques firstly Taguchi method coupled with Grey relational analysis and secondly Taguchi method in combination with desirability function (DF) approach has been applied in this paper. Comparison made between two hybrid optimization techniques are made to analyze to choose the best method. Optimal results have been confirmed by confirmatory experiment which showed satisfactory results.

  • Analysis and parametric optimization of flux cored Arc Welding process for IS 2062 mild steel plates using Taguchi method and utility concept
    Journal of Engineering and Technology, 2014
    Co-Authors: P. Sreeraj, T. Kannan, S. Maji
    Abstract:

    Optimization of flux cored Arc Welding (FCAW) process parameters were carried out to obtain optimum weld bead geometry in mild steel plates of IS 2062 by using an alternate Taguchi method. Design of experiments based on multi-objective Taguchi approach was employed for development of mathematical model correlating important process parameters like Welding voltage (V), Welding current (I), stick out (N) and wire speed (T), with weld bead parameters like penetration (P) and percentage of dilution as responses. The optimum Welding parameters were investigated using Taguchi method with L16 orthogonal array (OA). The developed models have checked for adequacy and significance based on analysis of variance (ANOVA) test. Because of high reliability, easiness in operation, high penetration good surface finish and high productivity FCAW became a natural choice for fabrication industries. Based on confirmation test, the proposed model can be effectively used to optimize the Welding performance. The utility concept was used for optimization of bead geometry and results are presented.   Key words: Flux cored Arc Welding (FCAW), optimization, analysis of variance (ANOVA), Taguchi approach, utility concept

  • Optimization of Flux Cored Arc Welding Process Parameter Using Genetic and Memetic Algorithms
    Journal for Manufacturing Science & Production, 2013
    Co-Authors: T. Kannan, N Murugan, B. N. Sreeharan
    Abstract:

    AbstractMost of the manufacturing enterprises indulge in the bonding of metals during the production process. This makes Welding one of the most important processes in industries. Subsequently, due to the high usage of Welding process, industrial engineers desire to optimize the parameters concerned to achieve the desired weld bead characteristics. This paper focuses on optimization of flux cored Arc Welding process parameters, which are used for deposition of duplex stainless steel on low carbon structural steel plates. Experiments were conducted based on central composite rotatable design and mathematical models were developed using multiple regression method. Further, optimization with objectives as minimizing percentage dilution, maximizing height of reinforcement and bead width was carried out using genetic algorithm and memetic algorithm. This problem was formulated as a multi objective, multivariable and non-linear programming problem. The algorithms were implemented using basic functions of C language making it highly reliable, adoptable, very user friendly and extendable to other Welding processes such as GMAW, GTAW, robotic Welding, etc. The adopted optimization techniques were further compared based on various computational factors.

  • Sensitivity Analysis of Flux Cored Arc Welding Process Variables in Super Duplex Stainless Steel Claddings
    Procedia Engineering, 2013
    Co-Authors: B Senthilkumar, T. Kannan
    Abstract:

    Abstract Weld surfacing with super duplex grade stainless steel found to improve corrosion resistance and functional life of the mild steel components used in the process industries. The properties of the deposited layer were influenced by the process variables that affect the heat input to the process. The influence exerted by the process variables on the responses of super duplex stainless steel claddings were modeled using the response surface models. The response surface models developed by the regression techniques using the data collected from central composite rotatable design of experiments. The data extracted from 32 single bead on the plate welds were deposited by flux cored Arc Welding process. The developed models can be used to predict and simulate the influence of the process variables on the responses. The insignificant variables found in the full models were removed by the backward elimination technique. Sensitivity analysis performed on the reduced models helps to identify and rank the process variables based on their extent of influence on the responses. Then the ranked variables are closely regulated to tailor the properties of the surfaced layer.

Chungsik Yoon - One of the best experts on this subject based on the ideXlab platform.

  • total and soluble metal contents in flux cored Arc Welding fumes
    Aerosol Science and Technology, 2009
    Co-Authors: Chungsik Yoon, Nam Won Paik, Jeonghan Kim, Hyun Byung Chae
    Abstract:

    The chemical composition and solubility of metals in Welding fumes is thought to be related to the welder health but is not well characterized. We quantified and compared the total (insoluble + soluble) and soluble metal contents in fumes from Flux-Cored Arc Welding using non-stainless steel (FCAW/NSS) and stainless steel (FCAW/SS) wire. Welding was performed in an American Welding Society standard fume collection chamber. The total content of 13 analyzed metals was significantly higher in FCAW/NSS fumes than in FCAW/SS fumes (51.6 ± 5.7 vs. 40.2 ± 5.2%, p < 0.001). Soluble metal content was significantly higher in FCAW/SS fumes than in FCAW/NSS fumes (15.5 ± 5.8 vs. 6.49 ± 2.4%, p < 0.001) due to the presence of potassium and sodium. Different proportions of each element were observed between Welding types. Iron, magnesium, and aluminum were significantly higher in FCAW/NSS fumes, whereas chromium, nickel, and potassium were more common in FCAW/SS fumes. The metal composition of FCAW fumes was more simil...

  • fume generation and content of total chromium and hexavalent chromium in flux cored Arc Welding
    Annals of Occupational Hygiene, 2003
    Co-Authors: Chungsik Yoon, Nam Won Paik, Jeonghan Kim
    Abstract:

    This study was performed to investigate the fume generation rates (FGRs) and the concentrations of total chromium and hexavalent chromium when stainless steel was welded using Flux-Cored Arc Welding (FCAW) with CO2 gas. FGRs and concentrations of total chromium and hexavalent chromium were quantified using a method recommended by the American Welding Society, inductively coupled plasma-atomic emission spectroscopy (NIOSH Method 7300) and ion chromatography (modified NIOSH Method 7604), respectively. The amount of total fume generated was significantly related to the level of input power. The ranges of FGR were 189-344, 389-698 and 682-1157 mg/min at low, optimal and high input power, respectively. It was found that the FGRs increased with input power by an exponent of 1.19, and increased with current by an exponent of 1.75. The ranges of total chromium fume generation rate (FGRCr) were 3.83-8.27, 12.75-37.25 and 38.79-76.46 mg/min at low, optimal and high input power, respectively. The ranges of hexavalent chromium fume generation rate (FGRCr6+) were 0.46-2.89, 0.76-6.28 and 1.70-11.21 mg/min at low, optimal and high input power, respectively. Thus, hexavalent chromium, which is known to be a cArcinogen, generated 1.9 (1.0-2.7) times and 3.7 (2.4-5.0) times as the input power increased from low to optimal and low to high, respectively. As a function of input power, the concentration of total chromium in the fume increased from 1.57-2.65 to 5.45-8.13% while the concentration of hexavalent chromium ranged from 0.15 to 1.08%. The soluble fraction of hexavalent chromium produced by FCAW was approximately 80-90% of total hexavalent chromium. The concentration of total chromium and the solubility of hexavalent chromium were similar to those reported from other studies of shielded metal Arc Welding fumes, and the concentration of hexavalent chromium was similar to that obtained for metal inert gas-Welding fumes.