Abstract: A process is disclosed for producing plasma type spray powders. The process involves forming, an admixture of a base metal, chromium, aluminum, and yttrium or master alloy powders containing these elements, and dry milling the admixture by high shearing to produce a homogeneous mixture. A slurry of this mixture and an aqueous solution of a binder is then spray dried to produce agglomerates, the major portion of which has a particle size of from about 20 to about 53 microns. This major portion is then separated from the remainder of the agglomerates and sintered in a reducing atmosphere to remove the binder and form a sintered powder. The sintered powder is then passed through a high temperature plasma reactor to melt the powder and produce a homogeneous plasma spray powder.