<p>In today’s rapidly developing manufacturing era, the requirement of corrosion resistant and lightweight components in various fields has increased exponentially. One such group of alloys that can meet these requirements is titanium alloys. This research will focus on Ti- 3Al- 2.5V alloy, more commonly referred as Grade 9 titanium alloy which offers superior strength and excellent corrosion resistance. It is also utilized in hydraulic tubing for aircrafts like Boeing. Wire electrical discharge machining (WEDM) which is an unconventional machining method has been utilized in this research to machine this alloy. Zinc-coated brass wire electrode was employed during machining. The WEDM input process parameters considered were pulse on time (<i>T</i>_on), pulse off time (<i>T</i>_off), wire feed (WF) and wire tension (WT). Taguchi’s L₁₆ orthogonal array was used to design the experiments. The performance measures observed were material removal rate (MRR), surface roughness (SR) and kerf width (KW). Multi-objective optimization of WEDM input factors was carried out by implementing Taguchi-integrated grey relational analysis (GRA). The optimal parametric combination to maximize MRR and minimize SR and KW was identified as pulse on time—9&#xa0;µs, pulse off time—12&#xa0;µs, wire feed—8&#xa0;m/min and wire tension—600 grams. Confirmation tests revealed that these optimization results hold good as the percentage of expected error was less than 5%. The influence of different input factors on the individual performance measures was examined by using the main effects plot created by Minitab 18 software. Scanning electron microscope (SEM) was utilized to visually compare the effect of optimized and unoptimized conditions (lowest ranked experiment) on machined specimens and corresponding wire electrodes.</p>