Abstract: The fume formation rate of flux cored wire in Gas Metal Arc Welding（ GMAW） is affected by many welding process parameters,which mainly includes welding current,welding voltage,welding speed and shielding gas flow rate. The methods of orthogonal test,single factor and interactive experiment are utilized to investigate the influence of welding process parameters on the fume formation rate and to obtain the optimal welding parameters to reduce the dust emission rate with the variance analysis,single factor analysis and regression fitting. The results show that the electric current is the predominant factor for welding fume generation. The predicated intendancy of fume formation rate with arc voltage and welding current is fitted for Boltzmann model,and the optimized welding process parameters are satisfied with the requirements of the welding process specification for the flux cored wire.