Current thermal spray chrome replacement and hardfacing materials primarily use WC or Cr 3 C 2 as hardphase materials and contain chrome. A series of cermet alternatives based on lower weight and cost ceramic particles including alumina, silicon carbide, boron carbide and titanium nitride were applied via HVOF and tested for wear and frictional properties under various loading conditions. Furthermore, based upon highly promising initial results, thermal spray particle designs were modified for lower cost and improved performance.