This study involves the optimisation of PVD - DC magnetron sputtering process parameters of zirconium base coating on Ti6Al4V alloy. The experiments were designed by utilising Taguchi's L9 orthogonal array. Multi-response attributes like coating thickness (CT), surface roughness (SR), and hardness (H) were optimised using grey relations and assignment of weight methods. The microstructural analysis using FESEM, surface topography using AFM, mechanical properties at the nano level using nanoindentation and wear tests were carried out for the optimised coatings to compare. The results indicated that the optimum coating parameters of 100 W - power, 10 sccm - argon flow, and RT (room temperature) provided a 75% increase in hardness, a 40% reduction in surface roughness, two times higher coating thickness and a 30% reduction in wear volume. The quality characteristics of the coating are significantly influenced by the substrate temperature followed by argon gas flow rate and power.
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