Abstract: Based on the theory of Linear Power Input (LPI), effect by the SAW process parameters on the weld seam dimensions as melting depth, residual height and melting width are discussed. The result shows that the welding LPI has a linear relationship with the welding melting depth, and that the residual height depends on both the welding parameters and the bevel shape, and can be well controlled. It is also concluded that the effect by the said welding parameters on the melting width is not as significant as that on the melting depth. In addition, an easy-to-do empirical formula for quick and correct estimation of welding material consumption is provided here in the article.