The need to improve the structural properties of materials in petrochemical industry, due to recurring failure, has motivated this study. The effect of deposition potential on structural integrity, surface topography and micromechanical progression of Zn based induced aluminium and TiO2 alloy coating series on mild steel was studied. The wear stability and microhardness behaviour of the developed composite coating was examined via, respectively, sliding reciprocating rig and dura scan diamond based microhardness tester. The structural reliability was inspected with scanning electron microscope equipped with EDS, and atomic force microscope. The results showed that the superb structural crystal resulted into a significant increase in the microhardness, and into a decrease in wear plastic deformation in a non-lubricated system. The precipitation of the deposits enforces stable crystal orientation and compact grains growth. The work has established that up to 13wt% TiO2 on zinc rich bath, a solid composite coating on mild steel, can be used to improve the service life of coating for stable structural properties.