The feasibility of using the HVOF process for the thermal spray-forming of free-standing components has been investigated. HVOF spray forming offers a number of potential advantages compared to the established procedure of plasma forming, including increases in component density, and reduction in material decomposition during spraying. Using blends of carbide and superalloy powders in various proportions, HVOF spraying has been successfully used to form free-standing cylinders and cones of various lengths and thicknesses. Microstructural examination of the spray-formed material, using optical microscopy and scanning electron microscopy (SEM), has shown a homogeneous distribution of carbides in the superalloy matrix, with very low levels of porosity. Vickers microhardness has been measured on several sprayed forms. In order to complete the study of the different systems, abrasion (Rubber Wheel Test), friction (Ball on Disk Test) and erosion wear results have been obtained. These wear results have been used in order to evaluate the behaviour of the sprayed samples with a different powder percentage in the blends. Corrosion tests have been done to evaluate the corrosion resistance of the sprayed samples (ASTM D-1411).

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