As a function of pulsed Tungsten Inert Gas (TIG) weld processing factor, authors have studied the relationship between dilution and mechanical qualities including impact toughness, notch tensile strength, hardness in the as-welded condition. Welds made with a pulsed TIG torch have a minimum notch tensile strength and impact toughness than the base metal (BM) because of the grains of the inter-dendritic network formed during the welding process. Weldments made from heat-treatable (Al-Zn-Mg) Aluminium alloys have their process parameters for pulsed TIG welding optimized employing the Taguchi analysis to get the best possible mechanical qualities. Notch tensile strength is shown to be inversely proportional to impact toughness.