The general method of process maps to understand and control thermal spray processes has been applied to monitor the deposition of WC-Co by high velocity oxygen fuel (HVOF). A selected number of particle state conditions (velocity and temperature) has been performed to produce a variety of coatings. Microstructure, mechanical properties, and wear resistance were evaluated and compared. A second order process map for sliding wear, impacting particle erosion and abrasive wear control can be constructed from the process map to provide the limits within which the particle state can be changed to achieve a predefined coating specification. The mechanisms behind the wear resistance are discussed within the framework of wear maps –third order process map-in the context of analysis of inter splat de-bonding, mechanical properties of the coating, and delamination failure.

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