In this work, as a model for manufacturing coating processes, the thermal and solutal magnetohydrodynamic (MHD) flow of a Sisko hybrid nanofluid (AA7072 and AA7075 nanoparticles dispersed in methanol) over a bilinear stretching sheet next to a porous medium is investigated. The model includes Forchheimer inertial drag effects, heat source, chemical reaction, and thermal radiation. The study also considers boundary conditions for convective heating. Using similarity transformations, a system of nonlinear ordinary differential equations is derived from the original nonlinear partial differential conservation equations. This system is solved with transformed boundary conditions using the MATLAB bvp4c solver, and the results are verified for consistency and reliability. Graphical representations are used to examine the effects of several control parameters, such as the Sisko fluid parameter, radiation parameter, magnetic field parameter, Forchheimer parameter, and Schmidt
number, on the transport characteristics. Using response surface method (RSM), we calculated the Nusselt and Sherwood numbers and the skin-friction components on the stretching surface. The results are confirmed using specific cases from previously published studies. According to the results, an increase in the Sisko fluid parameter increases the velocity profile, while it decreases the temperature and concentration profiles.
Furthermore, increasing the magnetic-field parameter increases the velocity boundary-layer thickness. R2 value using Sherwood number and adjusted R2 were equal to 100%. This study sheds light on the dynamics of nanofluids in MHD systems, which have significant consequences for energy generation, electronic cooling, processing of magnetic materials, and other areas of chemical and biomedical engineering that rely
on enhanced heat transfer.