Wire arc additive manufacturing (WAAM) offers significant potential for generating near-net shape components, especially on a medium to large scale, without the need for complicated equipment. However, the WAAM process's rapid deposition rate (1–10 kg/h) makes it difficult to achieve high-dimensional precision and tolerance. As a consequence, post-processing, such as machining, is often required to match industrial specifications. Despite the increased interest in WAAM, there is a lack of research that examines both the production and machinability of WAAM components, particularly in contrast to wrought equivalents under advanced lubrication strategies that align with sustainable tribological practices. This study is novel in providing a comprehensive, side-by-side comparison of WAAM and wrought Inconel 625 (IN625) under dry, mono, and hybrid nanofluid-assisted drilling an area that remains largely unexplored. The utilization of a newly synthesised hybrid nanofluid (hBN: Graphene in 1:2 ratio), together with extensive research of machining performance and tool coating degradation (by SEM/EDS), provides new insights into long-term lubrication strategies for additive-manufactured superalloys. Three lubrication conditions were investigated: hexagonal boron nitride (hBN), graphene based mono nanofluid (MNF), and a hybrid nanofluid (HNF), with their performance compared against dry machining. The nanofluids were thoroughly evaluated for dispersion stability, thermal conductivity, wettability, and dynamic viscosity. The hybrid nanofluid with a 1:2 ratio of hBN to graphene demonstrated excellent lubricating and cooling capabilities. During machining, the HNF showed considerable benefits over dry machining, including a 31 −" role="presentation"> − 34.15 % drop in cutting surface temperature ( T c). Similarly, the presence of HNF reducing surface roughness ( R a) by 21 −" role="presentation"> − 32 % and circularity deviation was minimised by 56 −" role="presentation"> − 59.05 % for wrought and WAAM IN625, resulting in improved dimensional accuracy. Additionally, tool wear ( V b) was decreased with less edge chipping and abrasive wear, resulting in a longer tool life. Notably, the study used TiN-coated tools, with tool wear and coating degradation assessed via SEM and EDS, providing insights into coating preservation under different lubrication conditions. Chip morphology study indicated smoother chips with fewer fractures and serrations, indicating less machining stress. These results show that hybrid nanofluids improve machining performance and sustainability, providing a novel route to optimize post-processing of WAAM components and advance environmentally responsible manufacturing.