Carbides are interesting materials for many wear resistant and high temperature applications, however, the production of coatings with these materials represents a significant challenge as they tend to oxidise or decompose into gaseous phases when they are exposed to extreme thermal spray conditions. An innovative method merging suspension and solution precursors was developed to allow the production of carbide composite coatings. Suspensions of carbides and borides were modified with the addition of oxide precursors to obtain composite coatings by high-velocity oxy-fuel (HVOF) thermal spray. The transformation of these oxides precursors and their subsequent melting during spraying contribute to protect the carbides from oxidising conditions, avoid their degradation during the spray process and support the development of dense coatings, as it was demonstrated by dispersive X-ray spectroscopy and X-ray diffraction analysis. The relationships between processing and microstructure were studied in terms of porosity phase distribution and mechanical properties, proving that this novel approach could be applied to obtain coatings of materials that are prone to decompose during thermal spraying.

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