A novel technique of using activated flux in Tungsten inert gas (TIG) welding is used in the present investigations. The influence of a hybrid multi-component surfactant, often known as flux, is explored in terms of depth of penetration (DOP), micro-hardness, tensile strength, and metallurgical characteristics. The activated TIG welding has been performed at three distinct levels of current, travel speed, and flow rate for workpiece materials of varying thicknesses. These three factors: current, travel speed, and flow rate. The results revealed a significant increase in the depth of penetration on using activated flux. The maximum value of the DOP was found to be 8.28 mm for the process parameters current 110 A, speed 82 mm/min and 12 L/min of flow rate. The conclusion that can be drawn from the findings of the tensile test is that A-TIG welding results in welds that have superior strength. Radiography revealed defect-free welds on using activated flux. The findings of this study provide evidence that demonstrates the viability of employing this economical method of welding in the process of combining thick sheets of SS-316 stainless steel to create an enhanced endowment.