Aluminide coatings were applied to UNS 30400 stainless steel coupons using the halide activated pack
cementation process. The aluminizing process was studied at two different temperatures with two
different activator salts - aluminum fluoride and aluminum chloride. The effect of process conditions, i.e.,
pack composition, pack size, process temperature, and activator salt type, on the coating characteristics
(microstructure, thickness, hardness, etc.) was investigated using different metrics, including mass and
thickness changes, microhardness, microscopy, and surface topography. Mass gain per unit area and
coating thicknesses were plotted as a function of temperature. The coating microstructure was evaluated
using optical microscopy, optical surface profilometry, and scanning electron microscopy coupled with
energy dispersive spectroscopy. In addition, X-ray diffraction was used to identify phases present in the
coating. Coated coupons were further characterized using Vickers microhardness. The surface
topography of the coated coupons was quantified.