This research aims to characterize the bead geometry, metallurgical aspects of the optimized maraging steel (250 grade) weld track processed by autogenous gas tungsten arc welding technique. Design of experiments was used to determine the weld track possessing optimal bead geometry. Welding speed and current were the parameters considered for optimization. Depth of penetration and bead width were the adjudicating parameters for optimality. Taguchi analysis showed that welding current is directly proportional to depth and width whereas weld speed was indirectly proportional. Statistical analysis indicated that welding speed has affected the depth of penetration and different current levels have affected the width of the weld bead linearly. Optical microscopy and SEM/EDAX analysis were done to investigate the post weld microstructural changes. X-Ray Diffraction were done to understand the phase formations. © 2017 Elsevier Ltd.