Abstract The process of metal joining for cladding is largely used in many process industries. Plasma transferred arc welding (PTAW) is accurate, and is easily available, with very low dilution and high volume of production. Computation of process equations by PTAW to predict the weld bead geometry is largely used in automatic PTAW. A five factor, five level technique used for the development of mathematical equations for the predicting the weld bead geometry for cladding SS410L (Cr-Si-Ni) onto carbon seat valve rings (ASTM A105) and is presented. The sufficiency and significance of the developed models by F test and t test have been checked respectively. To achieve the desired quality of overlay, the main and interaction effects of the control factors on dilution and bead geometry is presented. The mathematical model and the results obtained were optimized with conformity test. The artificial neural network model was developed to optimize the amount of metal deposited with regards to dilution.