WC-Co and WC-CoCr coatings were deposited with the JP-5000 liquid fuel HPIHVOF system using various thermal spray powder types. The microstructure, microhardness, deposition rate and wear resistance of the coatings were characterized. The results show that these coatings provide significantly more protection from dry three-body abrasion than from dry sand erosion, when compared to mild steel. They also provide more advantage at low angles of erosion than at high angles of erosion. Furthermore, the coating composition was found to have a significant effect on the wear rates, with WC-CoCr providing the best wear resistance even after taking the higher cost of the powder into account. The powder manufacturing route had only a secondary effect on the wear rates, except in the case of fused and crushed powder, which produced an inferior coating.

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