Hardfacing plays a major role in improving the material performance for longer life of component. While hardfacing, an important factor, dilution should be minimised by controlling the process parameters.The developed residual stresses within the hardfaced component due to hardfacing reduce service life of the component. Therefore, controlling the dilution, studying the effects of process parameters, and estimating the magnitude and nature of residual stresses are deemed necessary. Gate valve made of low alloy steel faces a serious problem of corrosion and erosion, which lead to leakage and premature failures. Co-based alloy, Stellite 6 was often selected as a hard-facing material deposited on the surface of gate valves due to its superior wear-resistance and heat-resistance properties. Among the various surfacing techniques, Plasma Transferred arc welding (PTAW) is selected for the fabrication of high quality intricate parts due to improved flexibility, productivity, and product quality in a manufacturing environment.