Microstructure and high-temperature friction and wear behavior of WC-(W,Cr)2C-Ni coating prepared by high velocity oxy-fuel spraying

► Sintering WC-20 wt.%Cr-7 wt.%Ni powder is effective in preparing WC-(W,Cr)2C-Ni composite powder. ► A double-decker shell-core microstructure forms in the as-sprayed WC-(W,Cr)2C-Ni coating. ► The double-decker shell-core microstructure plays a key role in improving oxidation resistance. ► Nano particles can be produced on the coating's surface during high-temperature wear tests. ► These nano particles can significantly improve wear resistance of the WC-(W,Cr)2C-Ni coating.