Along with machining parameters, in SAW, flux composition plays a deciding role for good quality weld. In the present study both factors were taken into consideration. SiO2-Al2O3-CaO flux system was used. In a SiO2 based flux NiO, MnO and MgO were added in different proportions. Experiments were designed according to Taguchi L9 orthogonal array, while varying voltage at two levels in addition to alloying elements. Voltage was considered as a noise factor. Using ANOVA, effect of each flux alloying elements was revealed for Vickers hardness and impact strength of the weld. Optimal levels of NiO,MnO and MgO were selected using S/N analysis. Voltage as a noise factor affected the impact strength most. Then the results of optimal conditions were verified by confirmatory experiments.