Dissimilar metal joints have gained appeal as a structural and pipe material for a variety of applications in industry due to their exceptional mix of mechanical features, including strength and corrosion resistance, at a cheaper cost. Due to the material's physical and chemical characteristics, choosing a joining procedure can be challenging. Because carbon precipitation and chromium loss result in an augmentation of porosity that affects the quality of joints and weakens strength, stainless steel joints of different grades are extremely important. In the current experiment, semi-automatic tungsten inert gas (TIG) welding methods will be used to weld duplex stainless steel (DSS) of grades 2205 and 2507. The geometry and configuration of the weld bead, as well as the type of welding procedure and other input factors like welding speeds, current, and voltage, are always determinants of the level of the weld bead quality. The mechanical characteristics and microstructural characteristics of welded joints will be scrutinised. The proposed tests will be carried out using a semi-automatic TIG welding machine. To determine the depth of penetration based on temperature variation, ImageJ software must be utilised. The input parameter values, namely base current (amps), peak current (amps), and welding speed (mm/min), should experimentally be set to the best values; any significant changes, tensile value, and testing process failures should then be analysed. For 4 mm thick dissimilar duplex stainless steel metal joints, the Taguchi design techniques are to be used to verify the optimal design parameters. © 2024 Elsevier B.V., All rights reserved.