One-step spray welding process was used to deposit Ni60 Ni-based self-fluxing alloy coating on 35CrMo wedge disc. According to different microstructure characters the cross-section of spray-welded specimen can be divided into three areas: spray welded coating, transition region and base metal. For the influence of welding thermo, base metal shows pearlite area, incomplete recrystallized area and original pearlite+ferrite area, the hardness of which is between 200HV to 165HV. The hardness of coating is about 865HV, which ensure good wear resistance. Because of the particles incomplete packing and the viscidity of melted metal, micro cavities formed near transition region and combine to form cavity chains, which will decrease the wear resistance and corrosion resistance of coating.