Coating of carbon steel with conventional and nano particle blended feedstock material is considered in relation to repair applications of rotating equipment. Gas Metal Arc Welding (GMAW) and Wire Arc Spray (WAS) processes are used to produce the coatings on carbon steel workpieces. The wire arc sprayed workpieces are heat treated at temperature similar to the operating temperature of hot-path components of power gas turbines. The microstructure and metallurgy of the workpieces are examined using the Scanning Electron Microscope (SEM), Optical Microscope, Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD). The indentation tests are carried out to assess the microhardness variation across the coatings. In the case of coatings produced by GMAW, it is found that fine structures are formed in the coating due to the presence of nano particles and they resulted in increased microhardness of the coatings. In the case of the wire arc sprayed workpieces, the formation of dimples like structure at the surface increases the surface roughness of the coatings. In addition, the microhardness of the resulting coating is significantly higher than that of the base material. The heat treatment does not alter the microstructure and microhardness of the coatings significantly.
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