A new Flame Spray gun HIJET™-9600 is developed which gives a supersonic flame. Shock diamonds are visible in the flame. Molybdenum metal was sprayed using the above mentioned equipment. The hardness of the sprayed molybdenum was compared to coatings by conventional flame spray methods. The coating was also evaluated for porosity, bond strength and phase distribution by X-ray diffraction. These results show better performance of the newly developed gun over the conventional flame spray process. This newly developed process is expected to provide an economical alternative to the HVOF process for spraying of metals and alloys.