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 an ongoing effort to develop coatings that improve the coefficient of friction. Compared 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, both of which are expensive materials. Some positive results of deposition using the amorphous powder encouraged the engineers and researchers. But in a few of the investigations on the air plasma spray Fe-based powder, the plasma generation gas is ordinary air. This innovation served to save on production costs. The aim of this work is the study of Fe-based spraying, applying the modification of a plasma torch. Both of the innovations help to enhance the hardfacing effect for wear resistance.