Abstract A suitable method for fabrication of superalloys is an important necessity in today’s world. In the current study microplasma welding has been explored due to its controlled heat input, cost effectiveness, high welding speed, adjustable pilot arc and most importantly small heat affected zone (HAZ). In this research, microplasma welding of 1 mm Inconel 625 is carried out in pulsed mode and optimized range of process parameters i.e. peak current and pulse width at welding speed of 4 mm/s. All other parameters were remained constant. Process parameters were optimized by experimental trial and error methods to obtain sound weld with no visible defects and characterization of the weld zone is carried out. Micro-structure analysis to evaluate the grain size and phase formed in the weld and HAZ zone was performed. Furthermore, hardness and tensile testing to characterize the strength of the weldment and fractographic analysis to study the type of fracture is carried out. The grains at lower peak current are fine and equiaxed while a slightly coarser and columnar as the peak current is increased. However, the weldments are found to have less ductility as compared to the base materials. This suggested that the compounds formed in the weld joints are composed of brittle carbides and nitrides. Thus, a relation between the microstructure and mechanical properties is proposed at the optimized process parameters range.