<p>This work focuses on the fabrication of Inconel-625 (IN-625) superalloy through wire-arc additive manufacturing (WAAM). Key process parameters, including the table travel speed, DC current, and wire feed rate, were optimized to achieve the desired microstructure and mechanical properties. Microstructural analysis revealed that the layer of the specimen showed fine primary grains transitioning to a dendritic core with a secondary arm structure, with intermetallic phases including Laves phases and Nb-rich gamma-nickel contributing to the observed strength variations. Tensile testing revealed that the samples processed at higher travel speeds exhibited the highest tensile strength along the build direction ~ (494&#xa0;MPa) and hardness ~ (457 ± 31.55 HV). The effects of WAAM process parameters and mechanisms on these outcomes were critically examined. Optimizing WAAM parameters is crucial for producing IN-625 alloys with refined microstructure, and enhanced strength, making them ideal for heavy-duty applications and advancing additive manufacturing techniques. </p> Graphical abstract <p></p>