A wear alloy coating (14) applied to a substrate material (12) by a cold spray process. Particles of the wear alloy coating material (16) are directed toward a target surface (18) of the substrate at a velocity sufficiently high for the particles to deform and to adhere to the target surface. The size and composition of the particles may be varied during the cold spray process to produce a coating with a varying property across the depth of the coating. Particles of the wear alloy material may be applied by cold spraying along with particles of a second material such as a lubricant or a ceramic material. For Group 5 hard facing materials, the size and distribution of the embedded carbide nodules may be controlled by controlling the selection of the carbide particles being sprayed. The cold spray process permits a wear alloy coating to be applied proximate a brazed joint or over a directionally stabilized or single crystal material without degrading the underlying material.