[OldBonus]

I'm pretty sure it's not normal. The tip should maintain an even shape all the way around.
That build-up around the tip looks similar to the hard carbon deposits and sooty material on my IACV. To remove it, I had soaked it in penetrating oil and using some steel wool and dull knife to scrape off the deposits. Very carefully did it as to not gouge or mark the original metal.

 

[OldBonus]

It was definitely not carbon deposits. For some reason it appears that someone welded a little dob onto the end. I hope I didn’t mess it up but I filed the weld down to a uniform shape trying to match the other side. Hopefully it works once I get it put back together.

Really odd why someone would weld the tip. But yeah, hopefully there is an improvement.
Here's what my IACV looks like after I had cleaned the tip.

And BTW, I didn't read in your post but do you have a check valve and rubber spacer that goes between IACV and intake manifold?

 

[OldBonus]

Yes I do. I have been wondering about that as well. Wondering it that is something that can be cleaned and reused.

Yes, you can re-use them if they are still in good working condition (rubber parts aren't torn or hardened). But if it's been in there awhile, I would recommend changing them out.

 

[OldBonus]

This inspired me to clean mine and I saw that mine has the same welded tip. I wonder if it was just a manufacturing artifact.

How is your idle?
This welded tip stuff is getting interesting, lol.