Thermal spray coating plays a significant role in industry. The wear-resistant deposition helps to provide a longer life cycle for the components. There is a small effort going into developing a coating that improves the coefficient of friction. Comparing with other deposition techniques, plasma spray coating can be recommended for a wide range of substrate materials to produce a stable, wear-resistant material. The plasma-sprayed deposition not only improves tribological performance but also embeds the desired mechanical and physical properties. In plasma spray technology, the inert gas used is mostly plasma jet. To create the wear-resistant coatings, the engineers apply self-flux or cermet powder, but these materials are expensive. Some positive results of deposition using the amorphous powder encouraged the engineers and researchers. But a few of the investigations on the air plasma spray using Fe-based powder used ordinary air as a potential substitution to save on production costs. The aim of this work is the study of Fe-based sparing involving the modification of a plasma torch, for which hardfacing provides the wear resistance.