In this present investigation degradation of mild steel (IS-2062 E250 CU) was protected by AA6063 as mechtrode using friction surfacing processes. To find the optimum process parameters 17 experiments were conducted by Design expert 14 using Box-Behnken design. Significant process parameters such as rotational speed of Mechtrode, traverse speed, and axial load were identified . Inter-metallic phases showed the occurrence of Al-Fe IMLs, such as Fe2Al5, AlFe3 that confirmed the Al-Fe-Si phases. Process parameters like axial force, traverse speed, and rotational speed were varied to obtain the response of coating thicknesses of 1.11 mm, 1.87 mm, 2.67 mm were subjected to acid, base (0.1 N,0.1 N) and sea water for corrosion studies. Nyquist and Tafel plot exhibited that medium spindle speed, traverse speed, and axial force parameters having 1.87 mm thickness surface existed at highly cathodic region.