ABSTRACT: The goal of this proposal is to demonstrate the feasibility of a novel environmentally-compliant process to produce an advanced alloy coating(s) that imparts excellent corrosion and wear resistance to structural metals on military aircraft and weapon systems. The resulting composite coating and the coating process do not consist of any hazardous materials such as heavy metals chromium (Cr), cadmium (Cd), beryllium (Be), nickel (Ni) and cobalt (Co) that are listed on the Office of the Secretary of Defenses (OSD) Emerging Contaminants WATCH List and/or ACTION List; BENEFIT: To eliminate hazardous materials in DOD manufacturing and maintenance locations ??To prolong the lifetime of metal parts used for military aircraft and weapon systems