This research reports the WEDM of heat treated Ti-6Al-4V by considering the pulse on/off duration, current, voltage and wire feed rate as machining parameters via Taguchi's L 25 array to assess the output responses i.e. material removal rate (MRR) and surface roughness (SR). It was observed that the material removal was significantly influenced with the change of wire feed rate at longer P-on (128 μs) and higher current (230 A). Lower wire feed rate (8 m min −1 ) and shorter P-off (51 μs) increased material removal more than that of higher wire feed rate (10 m min −1 ) with longer P-off (63 μs). Craters and globules of debris were viewed during all machining conditions on the machined surfaces. However, surface with maximum MRR (Trial 21, 59.021 mm 3 min −1 ) depicts droplets of molten materials, micro-cracks and micro-voids compared to deep and wide craters on the surface with minimum MRR (Trial 5, 2.973 mm 3 min −1 ) in SEM examination. The surface finish (1.301 μm) at lower value of P-on (112 μs) is always better than that at higher pulse-on-time (128 μs, 3.038 μm). Furthermore, the output responses were statistically investigated using analysis of variance (ANOVA) to evaluate the significant factors and contribution of each selected parameters.