Pulse Electrodeposition of TiO2–Graphene Oxide Coatings on Inconel 792: RSM Optimization for Enhanced Corrosion Resistance

Inconel 792 is a high-performance superalloy widely used in power generation systems, yet it remains vulnerable to corrosion under specific environmental conditions. This study presents the synthesis of a TiO2–graphene oxide (GO) nanocomposite coating on Inconel 792 via pulse electrodeposition. Process parameters—deposition cycles, anodic current density, and TiO2 concentration—were optimized using response surface methodology (RSM) to achieve a uniform surface. Characterization results indicated that sub-10 nm TiO2 nanoparticles were uniformly distributed on the GO sheets with close interfacial contact, which contributed to improved dispersion. Electrochemical tests revealed a significant enhancement in corrosion resistance: the optimized coating shifted the corrosion potential ( $$\:{E}_{corr}$$ ) positively from − 0.096 to − 0.050 V and reduced the corrosion current density ( $$\:{i}_{corr}$$ ) from 15.68 to 0.70 µA/cm2. Consequently, the polarization resistance (Rpol) increased approximately 16.46-times compared to the uncoated substrate, confirming the superior protective capabilities of the TiO2–GO nanocomposite against electrochemical degradation.