In order to address deficiencies in thermal spray coatings applied using air plasma spraying (APS) and high velocity oxygen fuel (HVOF), namely, adhesion, cohesion, porosity and line of sight limitations, novel hybrid coatings using post - thermal spray chemical vapor deposition via the pack cementation process were developed. Coatings based on tungsten carbide-cobalt chrome and chrome carbide-nickel chrome followed by boron or chrome diffusion were applied to multistage and single stage pump components for severe service applications in sand and alumina catalyst. Field testing established the effectiveness of using the dual coating approach.

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