<p>The objective of this research is to optimize welding parameters of wire arc additive manufacturing (WAAM) under which the application of Inconel 825 for marine components is feasible. The parameters such as welding voltage, wire feed rate, welding speed, nozzle to plate distance, weld gun angle and gas flow rate were systematically optimized using a Taguchi L9 orthogonal array to achieve complete metallurgical bonding. Inconel 825 is used as both base metal and filler wire in the welding process. From the experimental results, optimal welding conditions are identified as WS = 60 mm/min with WFR = 300 mm/min, provided a bead width of 6.4316 mm, Bead Height of 4.6098 mm, and a minimized penetration depth (PD) of 1.2654 mm. The hardness values were significantly improved, with H1 at 213.010, H2 at 197.848, and H3 at 205.031 for the top, middle, and bottom layers of the deposited material, respectively. The results indicate that welding speed (WS) and wire feed rate (WFR) are the two most influential parameters in optimizing weld quality, as confirmed by the regression analysis. According to the regression equation, WS and WFR are identified as the dominant factors, with statistical significance (<i>p</i>&lt;0.01) and a high correlation (R² = 0.97). Microstructural analysis indicated significant grain refinement, contributing to enhanced mechanical properties and weld strength. As such, there is a need for a more comprehensive approach that considers the combined influence of parameters like welding voltage, wire feed rate, welding speed, nozzle-to-plate distance, weld gun angle, and gas flow rate on the overall performance of the welds, particularly in marine conditions.</p>