The High Velocity Continuous Combustion (HVCC) Spray System was invented in 1993. The HVCC process uses wire as a consumable feedstock. Atomization takes place in a supersonic air jet, which is produced using a converging-diverging nozzle arrangement. The arc point is located within this supersonic air stream, which produces extremely finely atomized particles averaging 30 µm in diameter. The morphology of the HVCC produced coatings are homogeneous and consist of flat splat platelets with thin, adherent oxides. Permeation by gases and liquids through coating structures is significantly lower than that typically seen for twin wire arc spray coatings. Wear and erosion resistance of materials are significantly better than the same material applied with twin wire arc spray. The HVCC process has been successfully deployed over the past 7 years. It has been successfully used in confined space, in-situ applications, where traditional High Velocity Oxy-Fuel (HVOF) processes cannot be used for reasons of safety and practicality. These include applications in the petrochemical, paper and pulp, utility and independent power generating industries. Many other more specialized workshop and in-situ applications have also been performed with success.