This work is a novel attempt to identify the optimum process parameters in cold upsetting of Al–TiC metal matrix composites with multiple responses using grey Taguchi approach. The formation of barrel and workability are the important attributes that greatly influence the process of upsetting. Three independently controllable process variables, namely, aspect ratio, friction factor and load, each at four levels are considered to find their optimum levels which yields maximum barrel radius and workability simultaneously. Grey Taguchi analysis has been performed to optimize the levels of input parameters. Both the quality characteristics are improved significantly at the optimal process condition as verified by the confirmation test. The effect of individual process variables on the responses is determined using analysis of variance.

Cermet coatings were fabricated on AA5083 by D gun coating technique using three different combinations of powder feedstock namely WC–Co, WC–Co–Cr, and Cr₃C₂–NiCr. The effect of powder combinations on coatings’ phase composition, surface morphology, and cross-sectional microstructure were investigated using XRD, SEM, and EDS. Major findings revealed that WC–Co and WC–Co–Cr powders produced higher thickness with considerable surface defects compared to a coating that was produced by Cr₃C₂–NiCr powders. Moreover, a smooth compact and a uniform coating was obtained by using Cr₃C₂–NiCr powders. Electrochemical corrosion results showed that the OCP values of all the coated samples were shifted to a higher value than substrate and sample coated with Cr₃C₂–NiCr powder showed a stable OCP and more positive value than other coated samples. Similarly, the PDP curve of sample coated with Cr₃C₂–NiCr also showed lower corrosion current density at the cathodic region and better passivation behaviour in the anodic region.