The quality of cladded components depends on the weld bead geometry, coefficients of shape of welds and dilution, which have to be controlled. Optimum range of bead parameters and dilution are required for better economy and to ensure the desired mechanical and corrosion resistant properties of the overlay. The above objectives can easily be achieved by developing mathematical equations to predict the weld bead geometry. This paper presents the development of such equations using the data obtained by conducting three factor five level factorial experiments. The experiments were conducted by depositing Type AISI 317L flux cored stainless steel wire onto IS: 2062 structural steel base plate. The results of the confirmation experiments showed that the models developed are able to predict the bead geometries and dilution with reasonable accuracy. The studies have indicated that both main and interaction effects of the process variables play a major role in determining the bead dimensions and dilution, and the effect of interaction between the process variables cannot be neglected. The process parameters were also optimized using response surface methodology (RSM) which will help the plant engineers to select and control the process variables effectively, to achieve the desired clad qualities.