Thick tool steel coatings using HVOF spraying for wear resistance applications

►Oxygen flow was the most influencing HVOF process parameter identified by DOE. ►Thick and dense tool steel coatings (2 mm) can be deposited with low oxidation. ►Cold work tool steel coatings resulted in high hardness of about 712 ± 31 HV0.05. ►Thick cold work tool steel coatings exhibited superior abrasive wear resistance.