Surface Engineering is a topic of great relevance on today engineering. Surface features can be improved from the point of view of the material being depositing process. The present work, characterizes coating of nickel based hardfacing alloys, deposited by plasma transferred arc welding (PTAW) to on 316LN austenitic stainless steel substrate. the erosion, corrosion and wear properties of hardfaced components depend on the hardfacing weld pool, it have been controlled by the input process variables on the weld pool to enable effective control of these input variables. The above objective can be achieved by developing model to to predict the weld pool in terms of process variables. The design of experiment conducted to develop model, using five factor five level factorial design for Nickel based alloy (weartech-50) with austenitic stainless steel as substrate material. The models developed were checked for adequacy. Confirmation experiments were also conducted and the results shows that the developed model can be predict the weld pool reinforcement height with reasonable accuracy. It was identified from the investigation that the effect of the process variables on the weld pool is significant and it cannot be neglected. © Research India Publications. © 2012 Elsevier B.V., All rights reserved.