This study analyzes the effect of the process parameters such current, voltage, gas-flow rate and weld speed on a 10mm thick mild steel plate for minimum reinforcement height using the tungsten arc welding process. With the use of design expert, response surface methodology was applied in constructing a design matrix, analyzing the data and obtaining a mathematical model. The minimised weld reinforcement of 0.016mm was observed at a weld current setting of (200amp), voltage (18volt), gas flow

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... te (22L/min) and speed (4.5mm/sec) with a desirability value of 0.983. The analysis of variance (ANOVA) test performed to ascertain the adequacy of the model, showed that the welding current and gas flow rate had the most significant effect on the weld reinforcement.