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Response surface methodology based Grey relation analysis has been used to optimize the coating parameters of composite coating on aluminium based alloys. This approach gives the best combination of coating parameters to get maximum coating thickness, adhesive strength, microhardness, and minimum wear rate. For each response, the effect of coating parameters at different levels have been discussed. From Grey relation grade, the optimum parameters for better composite coating performance are found to be: temperature, 34 °C; current density, 1 A/dm2; and percentage of particle loading, 1.2 g/L. At 95% significance level, the Current density shows statistical significance on overall composite coating performance. [ABSTRACT FROM AUTHOR]