This study was undertaken with the objective of determining the effect of gap distance on the weld bead geometry and the mechanical properties of the weldments. Low-alloyed and low carbon steel plates were welded under different conditions where each weldment had different gap distance and weld bead grooves. The influences of welding parameters namely, welding speed, current and voltage on the weld bead were examined in terms of weld bead penetration and heat affected zone and weld metal zone hardness variations.