Scientists attempting to create a variety of tiny industrial components are very interested in AISI1018 mild steel due to its improved elasticity, low carbon content, and cost-effectiveness. For different technical and structural requirements, such as metal panels, engine components, highly pressurized chemical pipelines, machinery parts, and vehicle bonnets, the current research employs mild steel as a cornerstone matrix to generate Ni - Nano Al₂O₃ Coated AISI1018 Mild Steel Composites. In order to determine the ideal Ni - Nano Al₂O₃ wt. % that displays the best corrosion, mechanical, and surface morphology behavior, a Ni - Nano Al₂O₃ coating on mild steel with variable Al₂O₃ was applied using a reverse pulse electro deposition approach. According to research observations, increasing the proportion of Al₂O₃ on the exterior of mild steel has a considerable positive impact on mechanical behavior, abrasion resistance, and chemical resistance. Hardness of the HMSAL6 samples plated with 3% Al₂O₃ was 296 HV, which is almost 25% higher than the hardness of the plain samples. Similar studies on corrosion and wear have shown that a 25-40% improvement in corrosion and wear characteristics may be achieved by progressively increasing the amount of Ni-Al₂O₃. Through the use of field emission scanning electron microscopy, the efficiency of the reverse pulse electro deposition technique was also examined. It was discovered from the images that the surface of the mild steel is evenly distributed with the included Ni - Nano Al₂O₃

Keywords: AISI1018 Mild Steel, Nano Al₂O₃, Nickel, Pulse electro deposition approach, Corrosion behavior, Mechanical behavior, Structural applications