The surface properties of metals and alloys are usually altered by spray coating techniques for better performance in extreme conditions such as: erosive-corrosive and wear applications. In this study a wear and corrosion resistant coating composition of 75% Cr3C2-25% (Ni-20%Cr) was selected for cold spraying on N06601superalloy which can sustain in high-temperature applications. Microstructure properties of cold sprayed coating depend upon the composition and mechanical–physical properties of both coating and substrate materials, and cold spraying of brittle carbide-based materials is still a challenge for researchers. Various spray parameters were adjusted in this study to produce a 289 µm thick, smooth and dense (porosity less than 1) cold sprayed coating on 601-alloy with high hardness of 866 HV. For mitigating the erosion–corrosion phenomenon the coating microstructure is as important as its composition. This coating structure is suitable for further testing in high temperature and extreme corrosive conditions.
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