• Optimal laser cladding parameters for Ni-based coating on Ti-6Al-4V were determined using RSM: 1.8 kW laser power, 6 mm/s scanning speed, and 12 g/min powder feed rate.
• Laser power and scanning speed are the most influential parameters on coating geometry and dilution rate, while powder feed rate has a lesser effect.
• The optimized coating exhibits a fine dendritic microstructure with uniformly distributed hard phases, leading to a 45% increase in microhardness and a 60% improvement in wear resistance compared to the substrate.
• The developed regression models accurately predict coating characteristics, offering a reliable tool for process optimization in industrial applications.