In this investigation, spherical Cr7C3-(Ni,Cr)3(Al,Cr) powder with different compositions was prepared by vacuum melting and gas atomization. During the solidification process, Cr7C3 is in-situ synthesized and uniformly distributed in the Cr-doped Ni3Al phase. Coatings produced from the powders by HVOF spraying were characterized based on composition, microstructure, hardness, and tribological properties. The results show that the coatings compare well with commercial Cr3C2-NiCr coatings used on piston rings in heavy duty diesel engines. Optimization routes for further improvement are also discussed.

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