A new Plasma Transferred Arc(PTA) hardfacing process has been developed to obtain an overlay weld metal having excellent wear resistance. Effect of Ti, Ni and Cu metal powders addition on the surface characteristics of Aluminum alloy 5083 has been investigated with PTA process. Optimum overlaying condtions under which bead appearance is superior and porosities in overlaid metal are lesser are determined. This paper describes the results of tests on the performance of the overlay weld metal. The results are as fallow: (1) The mean hardness of the overlay weld metal is adjustable from Hv200 to Hv600 by PTA process. (2) Concerning defect of overlaid metals, blow holes were seen in Ni and Ti addition. Residual gas contents in blow hole for overlaid metals were confirmed as mainly H₂and a little of N₂. (3) The welding performance of this process is improved by use of DCRP plasma arc, which performs cleaning action on the base metal and weld metal. These results is an increase in welding efficiency. (4) The results of wear tests show that the weld metal has high wear resistance by the PTA process.