Arc welding is an indirectly controlled process where the electrical variables of arc are controlled to create joints of requisite mechanical and metallurgical characteristics after maintaining workable environment for the welder. Constant voltage arc types are mostly used in industry because they are energy efficient, more productive and welder friendly, these processes could be easily automated. However, the nature of arc types for CV processes appears drastically different for different metal transfer modes, input conditions, and process settings. The nonlinear arc itself poses as altogether different loads to power controller. Moreover, the process consists of several dynamic activities, each having different response time, their interaction with control variables add extra burden to controller. To simplify controller design, the input conditions of the process are defined in such a way that minimally defined two-input process could be controlled by controlling two independent dynamic activities. To meet that purpose with increased robustness this article proposes to use two independent easily implementable yet superior SOSM controllers—one for control of arc and another for control of wire feed speed. Robust control of wire feeding would reduce disturbance burden on the arc controller. The approach would be experimentally validated by practically designing both controllers along with creating requisite joints for wide range use suitable for ready-to-use in industrial applications. © 2021, Springer Nature Singapore Pte Ltd.