A new high density infrared based coating process has been developed to produce wear resistant coatings on AISI 4340 steel substrates that are of commercial interest. The process combines infrared heating, with power densities up to 35 MWm~(-2), with room temperature precursor spray deposition processes to rapidly form wear resistant coatings. Here, the process is demonstrated using a 20 vol.- percent WC reinforced coating in a Ni-11 wt-percent P binder on a AISI 4340 steel substrate, to produce a smooth, high density, 10 am thick coating with minimal degradation of the WC reinforcement or base steel and a hardness seven times greater than that of the substrate.
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