Abstract Alumina forming aluminide coatings have excellent properties with respect to liquid metal corrosion, tritium permeation barrier and high temperature oxidation/corrosion resistance. Aluminide coatings were developed over modified Grade 91 steel by pack cementation process at different temperatures using different pack compositions. The coated samples were characterized with respect to coating thickness, phases, hardness, and wear resistance. Change in the coating temperature greatly affects the evolved coating phases as well as coating thickness. The scratch tests were performed on the coated surface and on the X-sections to evaluate the wear behavior of the coated samples.