The aim of this work is to identify relationships between the input variables and the process responses and to develop predictive models that could be used in the design of coating AISI D2 steel substrate with TiC powder by a ball milling process. A ‘one-factor design’ combining a response surface methodology with a modified cubic model was employed to modelling and optimisation of key operating factors involved in the ball milling procedure. The mentioned experiment was performed by changing these three variables, milling duration in the range of 10–50 h, fine and coarse powder particle size and as-received and hardened substrate. Coating thickness, microhardness and scratch hardness number were defined as process responses. Predicted values of responses obtained by using this model were in good agreement with experimental values. Optimum condition (24 h milling, hardened substrate and fine powder particle) supported the respective experimental test.
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