Generally, the quality and properties of a weld joint is strongly influenced by welding variables during process. In order to achieve an ideal weld, it is important attention to bead geometry and microstructure evolution of weld metal. The effect of process variables on penetration and microstructure of C-80 steel joints produced by robotic CO2 arc welding was studied in present work. Different samples were produced by employing arc voltages of 23, 25 and 27 V, welding currents of 100, 110 and 120 A and welding speeds of 42, 62 and 82 cm/min. After welding process, geometric measurements were performed on welding specimens and the microstructural evolutions were investigated by optical observations of the weld cross sections. Results were clearly illustrated that increasing in welding current or arc voltage increases the depth of weld penetration. The highest penetration in this research was observed in 62 cm/min welding speed. The metallographic examinations also indicated that the microstructure of weld metal in all of specimens was composed mainly of martensite (M) and residual austenite (A) phases that a portion of martensite phase had been tempered.