Cermet coatings with Fe-based matrix as alternative to WC-CoCr: Mechanical and tribological behaviours

► Comparative study between HVOF-sprayed WC-FeCrAl and WC-CoCr cermet coatings. ► WC-FeCrAl layers: more oxidised, less hard but higher H/E ratio than WC-CoCr. ► HVOF parameters affect mechanical properties and sliding wear behaviour of WC-FeCrAl. ► Optimized WC-FeCrAl layers have comparable sliding wear resistance to WC-CoCr. ► No WC-FeCrAl coating approaches the particle abrasion resistance of WC-CoCr.