AbstractApplication of coatings by plasma vapour deposition involving electron beam evaporation and ion plating onto green powder metal compacts has been studied as a potential method for encapsulating powder metal products before hot isostatic pressing. The deposition of defect free coatings is essential if this concept is to provide a reliable encapsulation technique. Coating structures are therefore discussed in terms of the plasma processing conditions and surface roughness of the powder substrate. It is shown that the most promising approach is a combined coating and sinter–hot isostatic pressing cycle, which enables defects within the coating to be removed by the formation of a transient liquid phase.MST/1455