The paper focuses on developing mathematical models to predict grain size and ultimate tensile strength of pulsed current micro plasma arc welded Inconel 625 nickel alloy. Four factors, five levels, central composite rotatable design matrix is used to optimize the number of experiments. The mathematical models have been developed by response surface method. The adequacy of the models is checked by analysis of variance technique. By using the developed mathematical models, grain size and ultimate tensile strength of the joints can be predicted with 99% confidence level. Contour plots are drawn to study the interaction effect of pulsed current micro plasma arc welding parameters on fusion zone grain size and ultimate tensile strength of Inconel 625 weld joints.
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