The article presents the course and results of tests concerning plasma-powder surfacing of steels used in the power sector. The tests, involving the use of Inconel 625 alloy-based powder, aimed to determine the effect of process variables on overlay weld geometry, penetration depth and overlay weld-parent metal stirring degree. The article presents the results of metallographic examinations obtained by light microscopy, including the structure of overlay welds and Heat Affected Zone as well as the hardness distribution in overlay welds and Heat Affected Zone.