Highlights •Crack-free Ni-based coatings were fabricated by PTA-surfacing. •The Inconel 625 coating exhibits outstanding friction properties at 650 °C. •Deformed twinning mechanism under wear subsurface was identified as I-type twinning. •ABCBCACAB-type 9R phase originating from ITBs at wear subsurface is discussed. •Strengthening mechanism and its relationship with tribological performance are revealed. Abstract This study analyzed the strengthening mechanisms and friction properties of Inconel 625 surfacing layers fabricated by plasma transfer arc surfacing (PTA-surfacing) in ball-on-disc friction tests at room temperature and 650 °C. Results showed that Inconel 625 exhibited poor tribological performance at room temperature, but excellent at 650 °C. The average Vickers hardness of the high-temperature wear area (1.6826 ± 0.4059 GPa) was higher than that of the room temperature wear area (1.3900 ± 0.1875 GPa). The coefficient of friction for Inconel 625 decreased from 0.5362 at room temperature to 0.2846 at 650 °C. The wear rates of Inconel 625 at 650 °C and room temperature were 1.2063 × 10−5 mm3/N·m and 20.9740 × 10−5 mm3/N·m, respectively. The wear mechanisms at 650 °C were mainly abrasive, adhesion, oxidation wear, and some degree of delamination wear. The microstructural characterizations revealed that the wear subsurface at 650 °C comprised polycrystalline-mixed oxide layers (Ni(Cr,Fe)2O4, (Cr,Fe)2O3, and NiO), gradient grain refinement, nanoscale precipitations (M23C6, M6C, and laves), 9R structural phases, I-type twinning, and high-density dislocations, which synergistically enhance the outstanding high-temperature friction properties and strength.