Abstract: The present invention provides a process and product for applying a hard coating to corrugated roller shells, and other roller shells having an irregular outer contact surface with raised portions. The roller, together with the welding electrode and associated particle feeder are movably attached to a fixture that allows them to move with respect to each other. The electrode is positioned at a starting location, actuated to form a weld puddle into which the particles are fed, and moved along an application path that follows the raised portions.