The demand for high quality alloyed joints in aviation, automotive and power generative domain have led to the evolution of plasma arc welding process. In fact, nickel based super alloys is one such element that serves the purpose due to its extraordinary combination of high strength, oxidation and corrosion resistant properties even at extreme service conditions. However, fusion welding of Inconel 718 alloy is often associated with solidification cracking and fissure formation which challenges its weldability. Therefore, the present work is focused on presenting a detailed investigation on the influence of processing conditions on weld quality characteristics of Inconel 718 alloy. The design of experiments is framed such that the gas flow rate, welding speed along with current is varied for a constant arc voltage during plasma arc welding of Inconel 718 alloy. The processing conditions are varied in order to evaluate the macro and microstructural features along with micro-hardness attribute. Based on macro microstructural features and hardness attribute it can be assessed that plasma welding have immense potential to weld Inconel alloy without generating any major defects such as spatter, cracks, gas holes or porosity and it can be recommended for industrial application.