Wear protection coatings are required for highly efficient and economical steel components in plant, process, and power plant technology, which require wear protection coatings tailored to the application and steel material for high combined corrosive, tribological, thermal and mechanical stresses. Co-alloys are utilized as wear protection coatings for steel components, which are individually tailored to the application. The substitutability of Co alloys by Ni-based wear protection systems is a focus of research, considering the price and delivery risks as well as the increasing requirements for corrosive stress resistance at elevated temperatures. The optimization of the stringent machining conditions through alloy modifications of the welding flux for plasma transfer arc cladding (PTA) without compromising the wear protection potential, and utilizing the ultrasonic assisted milling process is a collaborative effort between BAM and ISAF at TU Clausthal (Fosta P1550/IGF 21959 N). The wear-resistant alloy NiMoCrSi (Colmonoy C56) is modified by alloying additions of e.g. Ti, Mo, Ni, Nb, Hf, and Al. The influence of different alloy additions on the wear potential is evaluated using the pin-roll test and the Miller test. In order to assess the wear characteristics, the microstructure is also taken into account as a result of the alloy additives. Ti leads to a star-shaped formation of the borides, and Nb to increased moulding. The microstructure changes have an influence on the wear resistance. In addition to the wear properties, the machinability of the wear alloys by ultrasonic milling is considered, as there is a growing demand in the industry for defined functional surfaces of high quality for this type of coating. A proficient surface machining process is imperative, for instance, to produce clearly defined contours and functional surfaces.