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Inconel 718 alloy has a wide range of applications in the aerospace sector because of its superior mechanical properties and its weldability. The machining of such higher strength materials with complex shapes is possible with wire electrical discharge machining. In the present research, an endeavor was made to enhance the machining process by utilizing zinc-diffused coating brass wire electrode and Taguchi-Data Envelopment Analysis-based Ranking (DEAR) methodology in the process while machining Inconel 718 alloy. Material removal rate, kerf width, and surface roughness were considered as the quality measures. The optimal arrangement of input factors in the Wire Electrical Discharge Machining (WEDM) process were found as 140 µs (Ton), 50 µs (Toff), 60 V (SV), and 5 kg (WT) among the elected factors with the error accuracy of 1.1%. The pulse-off time has the most significance on formulating the quality measures owing to its importance on deionization in the process.

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