Abstract The proposed configurations of non-consumable electrodes allow arcing with a diffuse cathode spot in a wide range of the welding current and exhibit longer service lives as compared to those of cone electrodes, which significantly enhance the arc welding characteristics in inert atmosphere. The effect of the geometric parameters of the electrode working area on the weld penetration depth, width, and geometric factor was investigated. It was found that the maximum value of penetration depth was achieved using the electrode with a slot in the working area and a cut along the welding direction, which enabled welding at relatively high speed and heat input leading to the formation of high-quality seams. The electrode with a cut across the welding direction exhibits the minimum penetration depth and maximum geometry factor and thus is most suitable for high-performance surfacing.