Ni–Cr–Si–B alloy deposition on 304 ASS is executed by making use of automated processes like PTA, laser cladding, etc., which are supportive in the mass production. However, for repairment and job-specific works, such processes become more expensive and hence cost-effective pulse-GMAW process is proposed. The effect of current on the coating characteristics is investigated. Microstructure reveals a eutectic structure near interface, which changes to a hypereutectic near the top surface. γ-Ni, carbides and borides phases are observed in coating, which increases hardness (529.3 HV1.0) and wear resistance (20 times). The present study reveals an inverse relation of hardness and wear resistance with current due to increased iron content in coating at higher current which suppresses boride formation.
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