A hybrid technique that combines plasma spraying and metal diffusion treatment was developed to improve the density, hardness, and adhesion of carbide cermet coatings. In this study, which was conducted to assess the process, Cr3C2-NiCr was deposited on stainless steel substrates by atmospheric plasma spraying. The test specimens were then embedded in a powder mixture of chromium, alumina, and ammonium chloride and diffusion treated. Cross-sectional SEM imaging, X-ray diffraction, and microhardness testing found the resulting surface layer to be extremely dense with outstanding hardness and exceptional bonding strength.

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