Metal Substrate Research Articles

Simplifying perovskite solar cell fabrication for materials testing: how to use unetched substrates with the aid of a three-dimensionally printed cell holder.

This work demonstrates that unetched substrates can be reliably used in perovskite solar cell (PSC) fabrication. Chemical etching and laser patterning of the bottom electrodes are time- and resource-consuming processes. In particular, when testing novel conductive substrate materials, such as metallic or bio-based substrates, etching or patterning could be entirely unfeasible or could require significant process optimization. Avoiding these steps could accelerate research on PSCs, yet the literature shows no attempts to override these steps. Here, PSCs were fabricated and characterized using three-dimensionally printed holders with spring-loaded pins. We show that devices made on unetched substrates have, on average, a similar performance to those made on etched substrates (16 ± 1% and 16.0 ± 0.7%, respectively). Our study provides a new strategy for fabricating PSCs, particularly when etching and laser patterning are impractical.

Improved SERS activity of TiN microstructures by surface modification with Au

Over the years, numerous outstanding research groups around the world have been working tirelessly on metallic SERS substrates. Although these efforts have led to the development of various sensors and pushed the field forward, today this line of research seems saturated and exhausted. In this work, we address this issue by exploring an emerging topic in recent literature: the fabrication of high-performance TiN SERS-active structures. TiN thin film was sputtered onto pyramidal Si microstructures. Spectroscopic ellipsometry measurements confirmed the plasmonic properties of the TiN material above its plasma wavelength of 515 nm. The Si-TiN surface was subsequently modified with an Au layer, which was then transformed into Au nanoparticles (Au NPs) during the Rapid Thermal Annealing process. The Si-TiN-AuNPs samples exhibited the highest extinction intensity, as well as the best SERS signal intensity for the model Raman reporter molecule. Further analysis of the SERS data showed that the presence of the Au thin film only moderately increased SERS activity, while Au NPs enhanced the SERS signal by one order of magnitude. Final Si-TiN-AuNPs platforms were successfully employed for the detection of vitamin B12, demonstrating a low limit of detection (8.57•10–8 M) along with excellent point-to-point repeatability.Graphical abstract

Anti-corrosive properties of vermiculite-enhanced waterborne epoxy resins with two-dimensional exfoliation

Abstract Although waterborne epoxy resin coatings are widely used in the field of anti-corrosion, micropores and micro defects in their coatings are the key factors restricting their further development. The exfoliated vermiculite was stripped by a physical one-step stripping method, with good water dispersion and dense lamellar structure. As the nano-filler, it can effectively fill the micro defects in the coating, make the coating structure more compact, and effectively prevent the intrusion of corrosive media. When exfoliated vermiculite was added at 1%, two orders of magnitude increased the electrochemical impedance modulus to 2.276×106 Ω cm2 and the corrosion current was correspondingly reduced to 1.186×10−8 A cm−2, showing excellent corrosion resistance. Adding 1% exfoliated vermiculite creates a “labyrinth effect” in the coating that extends the penetration path of the corrosion particles, thus effectively preventing corrosion of the underlying metal substrate. This enables the coating to better cope with harsh corrosive environments and provides a viable idea for coating protection.

Effects of multilayer MoS2 coating on the mechanical properties of metals: A competition between external force and interfacial adhesion

Molybdenum disulfide (MoS2) is a two-dimensional material that exhibits unique interfacial interactions with metals, making it potential coating material for improving material properties of metals. In this work, the effects of multilayer MoS2 coating on the mechanical properties and deformation behaviours of copper (Cu) and gold (Au) substrates are investigated by nanoindentation experiments and molecular dynamics (MD) simulations. Specifically, our experimental results indicate that the MoS2 coating greatly increases the Young's modulus and hardness of Au substrate throughout the indentation process. In the MoS2/Cu system, however, the MoS2 coating exhibits inverse effects at diffident indentation depths, which, specifically, has the weakening and enhancing effects at the early and late stages of the indentation process, respectively. MD simulations indicate that the different effects of the MoS2 coating on the mechanical properties of Au and Cu substrates are attributed to the different interfacial adhesion properties between the MoS2/Cu and MoS2/Au systems, as the binding energy of the MoS2/Au system is much larger than that of its MoS2/Cu counterpart. Moreover, it is also revealed in MD simulations that the load-bearing area of metal substrates can be significantly enlarged by the MoS2 coating, which leads to the dense dislocations distributed in metal substrates and thus the strain-hardening in MoS2/metal composites.

Recent Advances of the Ultimate Microbial Influenced Corrosion (MIC): A Review

Abstract: The persistent corrosion of metal surfaces poses a significant engineering challenge, including material degradation, loss of metal-structural integrity, and massive maintenance costs in various industrial, medical, and aerospace applications. Microorganisms such as archaea, bacteria, fungi, and microalgae can directly or indirectly influence metal corrosion. The degree of corrosiveness and corrosion healing varies depending on the microbe, medium, and metal substrate characteristics. Several attempts have been made to reveal answers to all questions about MIC. The published reports focused on testimonial failures and laboratory or field tests under varied situations. This review offers an overview of the most recent MIC research and emphasizes the scarcity of data on MIC detection, estimation, and the most recent approaches for MIC management. The review extends previously reported works and summarizes efforts for better understanding and cutting off MIC management in advanced technologies. Furthermore, it concludes with a final discussion of the current and future drawbacks and protective systems for preventing microbial-induced corrosion.

Theoretical investigations on hydroxyl carbon precursor fueled growth of graphene on transition metal substrates

Theoretical investigations on hydroxyl carbon precursor fueled growth of graphene on transition metal substrates

Structural basis of transcription: RNA polymerase II substrate binding and metal coordination using a free-electron laser

Catalysis and translocation of multisubunit DNA-directed RNA polymerases underlie all cellular mRNA synthesis. RNA polymerase II (Pol II) synthesizes eukaryotic pre-mRNAs from a DNA template strand buried in its active site. Structural details of catalysis at near-atomic resolution and precise arrangement of key active site components have been elusive. Here, we present the free-electron laser (FEL) structures of a matched ATP-bound Pol II and the hyperactive Rpb1 T834P bridge helix (BH) mutant at the highest resolution to date. The radiation-damage-free FEL structures reveal the full active site interaction network, including the trigger loop (TL) in the closed conformation, bonafide occupancy of both site A and B Mg2+, and, more importantly, a putative third (site C) Mg2+ analogous to that described for some DNA polymerases but not observed previously for cellular RNA polymerases. Molecular dynamics (MD) simulations of the structures indicate that the third Mg2+ is coordinated and stabilized at its observed position. TL residues provide half of the substrate binding pocket while multiple TL/BH interactions induce conformational changes that could allow translocation upon substrate hydrolysis. Consistent with TL/BH communication, a FEL structure and MD simulations of the T834P mutant reveal rearrangement of some active site interactions supporting potential plasticity in active site function and long-distance effects on both the width of the central channel and TL conformation, likely underlying its increased elongation rate at the expense of fidelity.

On the Aptness of Material Constitutive Models for Simulating Nano-Scratching Processes.

The simulation of nano-scratching on metallic substrates using smooth particle hydrodynamics (SPH) has been attempted by researchers in recent years. From a review of the existing SPH simulations of nano-scratching processes, it was found that mainly two different material constitutive models (i.e., the Johnson-Cook model and the elasto-plastic model) were employed to describe the material flow. In the majority of these investigations, the Johnson-Cook model was employed to characterise the stress flow of the material subjected to scratching. A natural question remains as to which material constitutive model is preferable for the SPH modelling of nano-scratching when quantitatively predicting the process outcomes. In this paper, a quantitative comparison of material responses during the nano-scratching of copper is reported when the process is simulated using SPH with two different constitutive material models, namely the Johnson-Cook and the elasto-plastic models. In particular, the simulated cutting and normal forces as well as the machined topography using both approaches are compared with the experimental work reported in the literature. The SPH-based simulation results in this paper are investigated based on the following three aspects: (a) cutting and normal forces with different material models and depths of the cut, (b) the effect of the cutting speed on forces and its dependence on adopted material models, and (c) the effect of adopted material models on the surface topography of machined nano-grooves. The SPH simulation results showed that using the Johnson-Cook material model, cutting and normal forces were closer to the experimental data compared to the results obtained with the elasto-plastic model. The results also showed that the cross-sectional profile of simulated nano-grooves using the Johnson-Cook model was closer to the experimental results. Overall, this paper shows that the selection of the Johnson-Cook model is preferable for the SPH modelling of the nano-scratching process.

Dropwise condensation performance of sprayable polymer/copper oxide composite coating

Even though dropwise condensation (DWC) has received significant attention for its potential to enhance heat transfer performance at a higher order than filmwise condensation (FWC), the scalability of durable DWC-promoting surfaces to sustain prolonged condensation remains challenging. The spray coating presents itself as a potential scalable method to deposit hydrophobic coating onto a metallic substrate. However, the conventional sprayable fluoropolymer exhibits poor adhesion to the substrate and thus requires a base coat before it can be deposited on a metallic substrate. To address this challenge, this study investigated dropwise condensation performance on a polytetrafluoroethylene/imide-based binder/copper oxide composite (PTFE/PI/CuO) coating that is deposited into a copper substrate using simple one-step spray coating and thermal annealing. The PTFE particles provide the necessary hydrophobic characteristics. At the same time, the polymer binder fills the pores between the particles, preventing droplet nucleation within the structure and minimizing the occurrence of flooding that can lead to undesirable droplet pinning. The PTFE/PI/CuO coating successfully promotes pinned-free dropwise condensation, leading to approximately two times higher heat transfer enhancement than filmwise condensation. Moreover, the formation of micro-scale hydrophilic CuO clusters at the top of the coating surface acts as nucleation sites that increase droplet growth rate and departure frequency without altering the droplet departure radius. As a result, PTFE/PI/CuO exhibits 1.4x times higher heat transfer over the PTFE/PI. Furthermore, a durability enhancement was obtained by adding sub-micron copper particles. While PTFE/PI coating failed after exposure to steam, no visible damage was observed from PTFE/PI/CuO, thus indicating enhanced durability. Moreover, the PTFE/PI/CuO composite also exhibited resistance against mechanical damage as its heat transfer performance remained similar even after being subjected to abrasion. Finally, the pull-off adhesion test revealed that PTFE/PI/CuO has higher adhesion strength than PTFE/PI, making it more suitable for dropwise condensation application.

Degradation analysis of plasma sprayed metal-supported solid oxide fuel cell: The evolution of electrode processes under polarization

Metal-supported solid oxide fuel cells (MS-SOFCs) prepared by plasma spraying exhibit promising potential for scale-up applications, where the key lies in breaking through the challenges of limited lifetime and durability. Although electrochemical impedance spectroscopy (EIS) has been widely used to unfold the complex electrode processes in electrochemical reactions, there are still some concerns concerning the in-depth understanding and scientific evaluation of the degradation mechanism of cell long-term performance. In this study, the contribution of each resistance to the overall performance degradation is separately determined by coupled equivalent circuit model (ECM) based on the deconvolution of recorded EIS data at different DC biases. It is found that the deterioration of cathode surface oxygen exchange and O2− conduction causes more than 64 % of the total resistance increase, followed by the anode charge transfer reaction and gas-phase transport (24.91 %), and then the ohmic resistance (9.73 %). However, the correlation between the output voltage drop of MS-SOFC under load and the gas-phase diffusion resistance gradually increases, indicating a shift in the cell degradation mechanism. Combined with the post-test characterization of the aged cell, it can be inferred that the degradation is mainly attributed to the densification of the anodic microstructure and the cathodic elemental segregation. Additionally, attention should be paid to the effects of the thickening of the metal substrate oxide layer and thermal mismatch on the structural stability of MS-SOFC.

Electrophoretic Deposition of Bioactive Glass Coatings for Bone Implant Applications: A Review

This literature review deals with the electrophoretic deposition of bioactive glass coatings on metallic substrates to produce bone implants. Biocompatible metallic materials, such as titanium alloys or stainless steels, are commonly used to replace hard tissue functions because their mechanical properties are appropriate for load-bearing applications. However, metallic materials barely react in the body. They need a bioactive surface coating to trigger beneficial biological and chemical reactions in the physiological environment. Bioactive coatings aim to improve bone bonding, shorten the healing process after implantation, and extend the lifespan of the implant. Bioactive glasses, such as 45S5, 58S, S53P4, 13-93, or 70S30C, are amorphous materials made of a mixture of oxides that are accepted by the human body. They are used as coatings to improve the surface reactivity of metallic bone implants. Their high bioactivity in the physiological environment induces the formation of strong chemical bonding at the interface between the metallic implant and the surrounding bone tissue. Electrophoretic deposition is one of the most effective solutions to deposit uniform bioactive glass coatings at low temperatures. This article begins with a review of the different compositions of bioactive glasses described in the scientific literature for their ability to support hard tissue repair. The second part details the different stages of the bioactivity process occurring at the surface of bioactive glasses immersed in a physiological environment. Then, the mechanisms involved in the electrophoretic deposition of bioactive glass coatings on metallic bone implants are described. The last part of the article details the current developments in the process of improving the properties of bioactive glass coatings by adding biocompatible elements to the glassy structure.

Alternating current electrophoretic deposition of maleic anhydride modified chitosan on Ti implants to combat biofilm formation

Chitosan, a cationic biopolymer, holds promise for diverse applications, including dental implant surface modification, due to its biocompatibility, non-toxicity, and antimicrobial properties. However, its limited water solubility at neutral pH complicates its use in alternating current electrophoretic deposition (AC-EPD). This study explores the novel use of water-soluble maleic anhydride modified chitosan (MA-CS) in AC-EPD to create antimicrobial coatings on titanium substrates. We optimize AC-EPD parameters for uniform MA-CS coatings and compare AC-EPD with conventional dipping. AC-EPD MA-CS coatings exhibit enhanced surface topography and amphiphilic, isotropic behavior, while other MA-CS-treated samples display anisotropic, monopolar behavior. We assess AC-EPD MA-CS-coated metallic substrates' biofunctionality, focusing on protein adsorption and antimicrobial properties. These coatings effectively adsorb proteins through diverse interactions with bovine serum albumin. To combat peri-implant diseases, we evaluate antimicrobial activity against oral bacterial communities, showing that AC-EPD successfully concentrates water-soluble MA-CS on titanium without compromising its biological performance. In summary, this study highlights AC-EPD as a versatile, efficient method for depositing polysaccharides in biomedical applications. It offers the potential for enhancing dental implant surface antimicrobial properties, addressing peri-implant diseases, and promoting overall dental health.

Influence of Bond Coat Roughness on Adhesion of Thermal Barrier Coatings Deposited by the Electron Beam–Physical Vapour Deposition Process

Thermal barrier coatings (TBCs) are effective protective and insulative coatings on hot section components of turbine engines. The quality and subsequent performance of the TBCs are strongly dependent on the adhesion between the coating and the metal substrate. The adhesion strength of TBCs varies depending on the substrate materials and coating, the coating technique used, the coating application parameters, the substrate surface treatments, and environmental conditions. Therefore, the roughness of the substrate surface has a significant effect on the performance of the TBC system. In this work, the roughness and microstructure of the 7YSZ (7 wt.% yttria-stabilised zirconia) top coat under different bond coat roughness treatments were studied. The purpose of this paper was to investigate the influence of the roughness of the bond coat on the adhesion of 7YSZ TBCs prepared by the electron beam–physical vapour deposition (EB-PVD) process. The VPA (vapour phase aluminium) bond coat was deposited on Inconel 718 nickel superalloy substrate using the above-the-pack technique. The ceramic top coat was applied to the bond coat using the EB-PVD process. The dependence between the TBC coating roughness and the bond coat roughness was determined. Adhesion strength measurements were performed according to the ASTM C 633 standard test method. The highest adhesion value observed in the tensile adhesion tests was 105 MPa. However, it was not determined whether the surface roughness of the bond coat affects the adhesion of the 7YSZ top coat.

Docking interactions determine substrate specificity of members of a widespread family of protein phosphatases

How protein phosphatases achieve specificity for their substrates is a major outstanding question. PPM family serine/threonine phosphatases are widespread in bacteria and eukaryotes, where they dephosphorylate target proteins with a high degree of specificity. In bacteria, PPM phosphatases control diverse transcriptional responses by dephosphorylating anti-anti-sigma factors of the STAS domain family, exemplified by B. subtilis phosphatases SpoIIE, which controls cell-fate during endospore formation, and RsbU, which initiates the General Stress Response. Using a combination of forward genetics, biochemical reconstitution, and AlphaFold2 structure prediction, we identified a conserved, tripartite substrate docking interface comprised of three variable loops on the surface of the PPM phosphatase domains of SpoIIE and RsbU that recognize the three-dimensional structure of the substrate protein. Non-conserved amino acids in these loops facilitate the accommodation of the cognate substrate and prevent dephosphorylation of the non-cognate substrate. Together, single-amino acid substitutions in these three elements cause an over five-hundred fold change in specificity. Our data additionally suggest that substrate-docking interactions regulate phosphatase specificity through a conserved allosteric switch element that controls the catalytic efficiency of the phosphatase by positioning the metal cofactor and substrate. We hypothesize that this is a generalizable mechanistic model for PPM family phosphatase substrate specificity. Importantly, the substrate docking interface with the phosphatase is only partially overlapping with the much more extensive interface with the upstream kinase, suggesting the possibility that kinase and phosphatase specificity evolved independently.

Development of anti-corrosion coating with sandwich-like microvascular network for realization of self-healing and self-reporting properties based on coaxial electrospinning

Biomimetic microvascular networks prepared by coaxial electrospinning technology have attracted much attention as a novel form of carrier for encapsulating active substances. However, the poor interfacial bonding strength between traditional electrospinning materials and metal substrates limits its application in anti-corrosion coatings. Herein, a novel poly(vinyl alcohol) grafted phytic acid (PVA-PA) electrospinning solution was synthesized. And a sandwich-like microvascular network (SMN) was prepared by coaxial electrospinning technology, which used PVA-PA solution as the shell material, epoxy resin 51 (E51), tetraphenylethylene (TPE) and polyamide resin as the core materials, respectively. Owing to the high porosity of SMN, epoxy resin can be directly spin-coated on it to form a composite coating (PVA-PA/SMN/EP). It is proved that due to the strong chelation and coordination interaction between PA and mild steel, the pull-out adhesion of the PVA-PA/SMN/EP composite coatings on mild steel was increased by 0.92 MPa. In addition, by systematically optimizing the relative viscosity, miscibility, conductivity, and saturated vapor pressure between the two jets of the core solution and the shell solution in coaxial electrospinning, the microvascular structure of the coaxial electrospinning nanofibers was improved and the fluidity of the internal active substances was maintained. When the PVA-PA/SMN/EP composite coating generates microcracks, the active substances encapsulated in the SMN flow out, in which the three-dimensional crosslinked network formed by the curing of E51 and polyamide resin enhances the spatial interactions between TPE molecules, which results in TPE emitting a bright blue fluorescence. This work provides a new approach for the development of the next generation of smart anti-corrosion coatings.

Electrosynthesis of Transition Metal Coordinated Polymers for Active and Stable Oxygen Evolution

AbstractTransition metal coordination polymers (TM‐CP) are promising inexpensive and flexible electrocatalysts for oxygen evolution reaction in water electrolysis, while their facile synthesis and controllable regulation remain challenging. Here we report an anodic oxidation‐electrodeposition strategy for the growth of TM‐CP (TM=Fe, Co, Ni, Cr, Mn; CP=polyaniline, polypyrrole) films on a variety of metal substrates that act as both catalyst supports and metal ion sources. An exemplified bimetallic NiFe‐polypyrrole (NiFe‐PPy) features superior mechanical stability in friction and exhibits high activity with long‐term durability in alkaline seawater (over 2000 h) and anion exchange membrane electrolyzer devices at current density of 500 mA cm−2. Spectroscopic and microscopic analysis unravels the configurations with atomically distributed metal sites induced by d‐π conjugation, which transforms into a mosaic structure with NiFe (oxy)hydroxides embedded in PPy matrix during oxygen evolution. The superior catalytic performance is ascribed to the anchoring effect of PPy that inhibits metal dissolution, the strong substrate‐to‐catalyst interaction that ensures good adhesion, and the Fe/Ni−N coordination that modulates the electronic structures to facilitate the deprotonation of *OOH intermediate. This work provides a general strategy and mechanistic insight into building robust inorganic/polymer composite electrodes for oxygen electrocatalysis.

Local high temperature phenomena near the complex interfaces of thermal barrier coatings based on non-Fourier model

Thermal barrier coatings (TBCs) consist of a metal substrate (Sub), a bond coat (BC), and a ceramic top coat (TC). The ceramic coating is a porous dielectric layer with a significant relaxation time that cannot be ignored. In high-temperature environments, an irregularly shaped thermally grown oxide layer (TGO) forms between the BC and the TC. Therefore, using non-Fourier model to describe the thermal contact process of TBCs with complex interface can get more accurate results. However, it is difficult to obtain the analytical solution of this model. This paper introduces a finite volume method based on unstructured meshes to address the non-Fourier heat transfer process in the complex interfaces of multilayer TBCs. The gradient reconstruction technique is employed to calculate the cell derivatives on the surface. The method's reliability is confirmed through a comparison with a two-dimensional analytical solution. The results indicate that the thermal wave travels at a limited speed within the TC layer. After passing through the interface, the thermal wave travels very fast within the BC and Sub layers, due to the influence of thermal wave reflection and superposition, obvious local high temperature will be formed near the interface. In addition, the effects of thermal conductivity, relaxation time and interface shapes on the non-Fourier heat conduction process of TBCs are also discussed. The results of this paper are useful for the structural design and failure mechanism research in TBCs.

Electrosynthesis of Transition Metal Coordinated Polymers for Active and Stable Oxygen Evolution.

Transition metal coordination polymers (TM-CP) are promising inexpensive and flexible electrocatalysts for oxygen evolution reaction in water electrolysis, while their facile synthesis and controllable regulation remain challenging. Here we report an anodic oxidation-electrodeposition strategy for the growth of TM-CP (TM=Fe, Co, Ni, Cr, Mn; CP=polyaniline, polypyrrole) films on a variety of metal substrates that act as both catalyst supports and metal ion sources. An exemplified bimetallic NiFe-polypyrrole (NiFe-PPy) features superior mechanical stability in friction and exhibits high activity with long-term durability in alkaline seawater (over 2000 h) and anion exchange membrane electrolyzer devices at current density of 500 mA cm-2. Spectroscopic and microscopic analysis unravels the configurations with atomically distributed metal sites induced by d-π conjugation, which transforms into a mosaic structure with NiFe (oxy)hydroxides embedded in PPy matrix during oxygen evolution. The superior catalytic performance is ascribed to the anchoring effect of PPy that inhibits metal dissolution, the strong substrate-to-catalyst interaction that ensures good adhesion, and the Fe/Ni-N coordination that modulates the electronic structures to facilitate the deprotonation of *OOH intermediate. This work provides a general strategy and mechanistic insight into building robust inorganic/polymer composite electrodes for oxygen electrocatalysis.

Self-stacked small molecules for ultrasensitive, substrate-free Raman imaging in vivo.

Raman spectroscopy using surface-enhanced Raman scattering (SERS) nanoprobes represents an ultrasensitive and high-precision technique for in vivo imaging. Clinical translation of SERS nanoprobes has been hampered by biosafety concerns about the metal substrates used to enhance Raman signals. We report a set of small molecules with bis-thienyl-substituted benzobisthiadiazole structures that enhance Raman signal through self-stacking rather than external substrates. In our technique, called stacking-induced charge transfer-enhanced Raman scattering (SICTERS), the self-stacked small molecules form an ordered spatial arrangement that enables three-dimensional charge transfer between neighboring molecules. The Raman scattering cross-section of SICTERS nanoprobes is 1350 times higher than that of conventional SERS gold nanoprobes of similar particle size. SICTERS outperforms SERS in terms of in vivo imaging sensitivity, resolution and depth. SICTERS is capable of noninvasive Raman imaging of blood and lymphatic vasculatures, which has not been achieved by SERS. SICTERS represents an alternative technique to enhance Raman scattering for guiding the design of ultrasensitive substrate-free Raman imaging probes.

Enhancing Tribological Characteristics of Titanium Grade-5 Alloy through HVOF Thermal-Sprayed WC-Co Nano Coatings by TOPSIS and Golden Jack Optimization Algorithm.

Thermal spray coatings have emerged as a pivotal technology in materials engineering, primarily for augmenting the characteristics related to wear and tribology of metallic substrates. This study aimes to delve into applying High-Velocity Oxygen Fuel (HVOF) thermalsprayed WC-Co nanocoatings on Titanium Grade-5 alloy (Ti64). The coating process, utilizing nano-sized WC-Co powder, undergoes systematic optimization of HVOF parameters, encompassing the flow rate of carrier gas, powder feed rate, and nozzle distance. Experimental assessments via Pin-on-Disc (PoD) tests encompass Loss of Wear (WL), Friction Coefficient (CoF), and Frictional Force (FF). Later, an exhaustive optimization of responses is conductede using the Technique for Order Preference by Similarity to the Ideal Solution (TOPSIS) method and the golden jack optimization algorithm (GJOA). Outcomes show a substantial increase in WL, CoF, and FF with a rise in the carrier gas and powder feed rate. However, with increasing spraying distance of powder, the WL, CoF, and FF tend to lower due to higher bonding, which leads to increased wear resistance. The ideal parametric settings achieved from TOPSIS and GJOA are 245 mm of spray distance, 30 gpm rate of powder feed, and 11 lpm of carrier gas flow rate. The powder feed rate contributes 88.99% to the control action, as seen from ANOVA. The confirmation experiment presents that the WL, CoF, and FF output responses are 42.33, 27.97, and 9.38% less than the mean of experimental data. These results highlight the HVOF process in spraying WC-Co nanocoatings to fortify the durability and performance of Ti64 alloy that can be patented for diverse engineering applications.