HVOF sprayed WC-Co(Cr) coatings are typically used to prevent wear and corrosion. In order to improve coating properties and economical efficiency of coatings, process development of feedstock powders and spraying processes are required. Denser coatings with reduced as-sprayed surface roughness were obtained by reduction of carbide and agglomerate sizes. According to early studies, using the conventional HVOF process damages the desired nano-structure during spraying. Therefore, in this study a new thermal spray system called CJS (Carbide Jet Spray) was utilised. CJS has colder process parameters, so the structure of fine particles and their properties are more easily preserved. Commercial and experimental powders with different carbide and particle sizes were sprayed with CJS and the resulting coatings were analysed.
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