To fabricate the high-grade coating, HVOF is commonly used because of its potential to form dense deposits with low porosity and low oxide content. Due to higher kinetic power, a shorter dwell time, and lower flame temperatures, HVOF spraying provides a more desirable composition for dense coatings and regulates the phase transitions of the powder particles than plasma spraying. Because of the proper balance of hard-phase WC particles and the strong and durable metallic matrix cobalt chromium, WC–Co–Cr is an effective coatingmaterial for minimizing abrasive wear (Co Cr). Process variables such as liquefied petroleum gas flow rate, oxy flow rate, spray distance, carrier gas rate of flow, and feed rate of the deposition powder material all have a role in coating performance. In this work, a five-element central composite design (CCD) was utilised to reduce the number of trials by encompassing all possible combinations of process variables. A mathematical model was used to determine the porosity and micro hardness of the coatings, as well as the high velocity oxy fuelprocessing variables, and the model’s appropriateness was assessed using an analytical variable. The response surface methodology has been used to optimize process parameters (RSM).