Abstract: Generally, the quality of a weld cladding is directly influenced by the welding input parameter settings. Selection of proper process parameters is important to obtain the desired weld bead profile and quality. Corrosion is the tendency of a metal to return to its most stable thermodynamics state with the most negative free energy of formation. Most simply stated, it is a chemical reaction of the metal with the environment to form an oxide, nitride, carbonate, sulphate or other stable compound. This study addresses the modeling parameters in FCAW process using set of experimental data and multiple regression analysis. The input process variables considered here include wire feed rate (F), welding speed (S), nozzle to plate distance (N) and weld gun angle (T) each having five levels. The process output characteristics are weld bead width (W), height of reinforcement (R) and depth of penetration (P). The regression modeling is used in order to establish the relationships between input and output parameters. In this research work, the developed models were examined for their adequacy. The result shows that the models can predict the weld bead geometry with reasonable accuracy.