In surface modification applications, cermets such as Cr3C2–NiCr are used to enhance the wear resistance of the substrate. Friction surfaced cladding is a recently developed solid-state surface modification process in which the deposition of the clad layer is accomplished below it’s melting temperature, so that degradation of the substrate is minimized. The present investigation discusses the friction surfaced cladding of Cr3C2–NiCr using consumable die steel rod. It was observed from the micrographs, that with the suitable combination of tool plunging rate (plunging speed), tool rotational speed and traverse rate, successful cladding of Cr3C2–NiCr was achieved. A plan of full factorial experiment was followed for determining the process variables for the successful deposition of Cr3C2–NiCr clad layer with the substrate. A mathematical model was developed to predict the composite clad dimensions and microhardness with respect to the process variables. Depending upon the process parameter, it was observed that the hardness of the clad and clad geometrical feature varied. The microstructural analysis exhibited sound and uniform bonding of clad layer to the substrate and near uniform distribution of Cr3C2–NiCr. Desirability based multi-response optimization procedure was followed to arrive at optimized Cr3C2–NiCr clad. © 2016, The Indian Institute of Metals - IIM.