This paper presents research results showing how spraying distance affects the bonding strength, porosity, microhardness, and deposition efficiency of HVOF-sprayed NiCrAl coatings. The coatings examined were deposited on quenched 1045 steel substrates at spraying distances of 340, 360, and 380 mm. At the optimal standoff distance of 360 mm with kerosene and oxygen flow rates at 22 L/h and 850 L/min, respectively, NiCrAl coatings were achieved with a bonding strength of 66 MPa, microhardness of 418.56 HV0.3, porosity of 1.1%, and deposition efficiency of 65.3%.

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