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Mechanical strength of the weldments is not only influenced by the composition of the metals but selection of process parameters and weld bead profile also play a vital role in determining the strength. The relationships between the process parameters and the bead parameters controlling the bead shape are to be established. This is achieved by the development of mathematical expressions, relating the weld bead dimensions to the important process control variables affecting these dimensions. Also, optimization of the process parameters to control and obtain the required shape and quality of weld beads is also made possible with these expressions. The pulsing current parameters on weld pool geometry namely front height, back height, front width and back width of pulsed current tungsten inert gas welding (PCTIG) of titanium alloy was analyzed. Box–Behnken design was used to develop empirical relationships, incorporating pulsed current parameters and weld pool geometry.