The High Velocity Oxygen-Fuel (HVOF) process has recently increased interest in tungsten carbide (WC) coatings for enhancing surface properties of lightweight alloys such as Al6061, widely used in aerospace, automotive, and industrial applications. In this research work, an investigation into the microstructural characteristics, hardness improvements, Coefficient of friction (COF), and reductions in wear rate of the WC coatings applied at a thickness of 100 microns and 200 microns on Al6061 alloy is discussed. Scanning electron micrographs show a dense and uniform WC layer with minimal porosity. EDAX confirmed the presence of WC and supporting elements. In the case of the 100-micron coating, there was an increase of 337.5% over the base alloy, and in the case of the 200-micron coating, the improvement was 525%. The COF was reduced by 22.5% and 30.9%, and the wear rate decreased by 25% and 41.6% for the respective coating thicknesses.
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