Abstract Weld bead geometry parameters are significantly affected by polarity as it affects the extent of heat generated at electrode wire and work in the welding process which further influences the mechanical and metallurgical properties. Essential requirement of a welding process is to obtain a weld joint with desired weld bead parameters and mechanical properties. In present study mathematical models have been developed to evaluate the effect of polarity on weld bead geometry in submerged arc welding. Response surface methodology has been used for predicting the critical dimension of weld bead geometry and shape relationships at straight polarity and reverse polarity. The developed models have been checked for adequacy and significance by F-test and t-test. Effect of polarity on the response parameters are presented graphically which not only leads to prediction of weld bead geometry and shape relationships but also assisted to achieve the control over weld quality by selecting the appropriate process parameters.