Conventional (micron size) and Nanostructured (multimodal) WC-Co powders were sprayed on Al alloys using JP 5000 HVOF system. The coating microstructural characteristics and phase composition were investigated using SEM and XRD. The morphology and microstructure of nano-powders were also analyzed by SEM and XRD. The crystal size of the different phases was also investigated. The results show that nano-structured coatings have additional phases of W2C beside WC phase. Abrasion and hardness resistance of the coatings were also investigated. The results show that the wear and hardness resistance of the nanostructured coating is higher than the Conventional coating.

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