Abstract : The work attempts to find the effect of different parameters such as load, sliding speed, sliding distance and pin temperature on wear rate of composite coating. Ni and Al2O3 are used as composite coating materials which are deposited on the aluminium alloy Al-6061 substrate. Samples are prepared by using electro co-deposition technique. Taguchi L27 orthogonal array is used to optimize the process variables. Main effect plots and interaction plots are drawn to know the variation of wear rate with different parameters. Contour plots show the regions where the minimum and maximum wear rate occur with respect to pin temperature. Wear analysis has been made by using Taguchi’s L27 orthogonal array. The optimum values are noticed for load, sliding speed, sliding distance, and temperature are 0N, 200rpm, 500m and 40 oC respectively. Wear analysis also has been made by using Improved Taguchi method. The optimum values are noticed for load, sliding speed, sliding distance, and temperature are 0N, 200rpm, 000m and 40oC respectively.