HVOF and plasma spray processes were used to spray Cr3C2-NiCr Coatings. The coatings were characterized by x-ray diffraction, porosity, hardness, adhesive strength, thermal shock and cup tests. As a result, HVOF spraying can produce a coating with more stable phase structures, lower porosity, higher hardness, better adhesive strength, better toughness and higher erosion resistance. The HVOF sprayed coating had been successfully used in hearth roll of continuous annealing process lines (CAPL) in Baoshan steel & iron cooperation. Key Words: thermal spray, HVOF, plasma, Cr3C2-NiCr

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