Purpose : Submerged arc welding (SAW) is a common arc welding process where the total welding cost includes the cost of the flux consumed during welding, SAW is preferable more its inherent qualities like easy control of process variables, high quality, deep penetration, smooth finish. Flux used in submerged arc welding contributes a major part towards welding cost. In the present work, the effect of operating voltage, welding current, welding speed and basicity index on flux consumption has been studied. Flux consumption for each bead was weighed. Although the physical and chemical properties of SAW fluxes have been studied widely, very little attention has been paid to the factors that affect its consumption. Design/Methodology and Technique : The experiment was designed based on a five level factorial central composite rotatable design with full replication . The experimental calculations and results graph was conducted as per the design matrix using Design Expert Software. The response surface methodology (RSM) is a set of techniques that encompasses (i) the designing of a set of experiments for adequate and reliable measurement of the true mean response of interest; (ii) the determining of mathematical model with best fits; (iii) finding the optimum set of experimental factors that produces maximum or minimum value of response; and (iv) representing the direct and interactive effects of process variables on the bead parameters through two dimensional and three dimensional graphs.