In this work, WC–10Co–4Cr coatings were separately deposited on 300M steel by high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) spraying processes. Microstructure, porosity, micro-hardness, bonding strength, wear and corrosion resistance of the coatings after different processing were investigated and compared. The result shows that dense and homogeneous microstructure existed in both two WC–10Co–4Cr coatings. Owing to lower temperature flames and higher particle velocity in the HVAF process, the HVAF-sprayed WC–10Co–4Cr coating exhibited less decarburisation, lower porosity (0.74%), higher micro-hardness (1162 HV_0.3) and bonding strength (74.68 MPa) than HVOF-sprayed WC–10Co–4Cr coating. In addition, wear and corrosion resistance of these two coatings were evaluated by sliding wear test and electrochemical corrosion test. The HVAF-sprayed WC–10Co–4Cr coating also exhibited excellent wear resistance and superior corrosion property than HVOF-sprayed WC–10Co–4Cr coating.

A novel Ti/Al lightweight graded material was fabricated successfully using the direct laser deposition process, with the composition continuously changing from 100 vol.-% Ti6Al4V to 100 vol.-% AlSi10Mg. Microstructures and phase transformations were characterised, and the mechanical properties of the Ti/Al lightweight graded material were investigated. It was found that element concentrations followed a nearly linear relationship along the compositional gradient. The maximum hardness reached 619 HV in the ‘II’ zones, and then it decreased gradually to 214 HV at the outermost layer, with the increase in the proportion of AlSi10Mg. The values for the ultimate tensile strength were above 400 MPa, and the fracture surfaces indicated a transition from ductile to brittle fracture along the graded direction.