Abstract To avoid the activated radiation of cobalt-based alloy, a new cobalt-free Fe-based alloy powder (FeCr-1) has been developed. In addition to the main constituent of Fe, this powder contains C, Ni, Cr, B, Si, W, V, Mo, Mn, etc. By using a hollow laser, FeCr-1 has been successfully prepared on the surface of stainless steel as the cobalt-free strengthening layer. Investigation reveals that the microhardness of this laser cladding coating corresponds to that of cobalt-based alloy Stellite 6. The XRD result reveals that the primary phases of, Fe 2 SiV, Ni 2 Si and Si 2.2 Mn 6 as well as various fine carbides such as Fe 0.4 Mn 3.6 C, Fe 3 C and Fe 5 C 2 exist in the coating. Analysis indicates that this kind of alloy has some advantages of high wear resistance, good corrosion resistance and high temperature tolerance. The capability of the Co-free FeCr-1 alloy powder is close to that of Stellite 6, thus it could be the promising candidate material of bead welding used for the new generation nuclear power valves.