The interconnected usefulness of titanium grade 5 is amplified by the improved mechanical ability and sustainable applications in various industries like the aerospace, medical industry and many more. Despite the profound properties of Ti6Al4V, it is worthy of intellectual study to investigate the possible performance improvement of the material for better operational application. This study adopted the use of RF magnetron sputtering to deposit the target on the substrate material under varying temperatures and deposition power. A total of four samples and control were analyzed for a surface morphological examination and post-sputtering chemical compositional analysis via SEM (scanning electron microscope) and EDX (energy dispersive x-ray analysis). Further investigation on the samples' crystallites was done using XRD (X-ray diffractometer). The SEM images showed low agglomeration and most of the samples were void of pores, cleft and crevices, which implied homogeneous distribution of the target (Inconel thin film) on the titanium substrate. The EDX of the Inconel coated titanium samples revealed elements such as Ti, Si and C, which are beneficial to the properties of the materials. The XRD profiles of the Inconel coated titanium samples disclosed intensities of high peaks, which indicated stability, chemical and microstructural homogeneity of the thin film.

Friction Stir Welding (FSW) is a relatively new solid state joining technique which is used not only for joining the aluminum and its alloys but also has potential for joining dissimilar materials with very different physical and mechanical properties which are hard to weld using conventional fusion welding processes. Tensile shear testing is used to determine the Mechanical strength of friction stir lap (FSL) welds under static loading, fracture strength (σLap) corresponding to the maximum load in a test over the sample width is widely used as the strength value. During friction stir lap welding (FSLW) of dissimilar metals with large differences in melting temperatures, a metallurgical bond is established through the formation of interfacial intermetallic compounds. However, as these intermetallic compounds are generally believed to be brittle with little ductility, they are generally considered to have detrimental effect on fracture strength. The aim of the present research is to study how the interface structure is affected by FSW parameters and how the formation of interface structure affects fracture of Al-Steel and Al-Ti FSL welds.

In this study, the efficiency of integration between Taguchi and TOPSIS in multi-response optimi-zation of powder mixed electrical discharge machining (PMEDM) process was evaluated. The in-put parameters, such as workpiece and tool electrode material, polarity, pulse on time (ton), pulse off time (toff), Current (I) and powder concentration have been selected to optimize two responses; namely surface roughness (Ra) and surface hardness (HV). The results show that titanium powder mixed dielectric fluid improves multi-response optimization efficiency in PMEDM. In addition, machining conditions, such as tool electrode material, powder concentration, pulse on time, polarity, current density, A×G and B×G interactions play a very important role on S/N ratio of C* whereby powder concentration has the strongest influence. TOPSIS -Taguchi is a potential method for multi-response optimization in PMEDM. However, the optimal results using ANOVA analysis show that there is a necessity to have more studies in TOPSIS-Taguchi to improve the in-tegration efficiency between two methods for optimizing multiple responses in PMEDM.