Because of the unique characteristics of thermal spraying processes, they received much attention in industrial applications used in power plants, oil fields, drilling operations, petrochemical plants, mining industries, and cement production plants. Depending on the applications and working conditions of the components of industrial equipment, some of these components are required to have superior properties such as wear resistance, corrosion resistance, fatigue life, residual compressive stress and toughness for extreme loadings. When tungsten carbide (WC) coatings with cobalt or nickel matrix are deposited by HVOF process, depending on the selected parameters (independent variables) and their effect on the particle parameters (dependent variables), they may possess favorable properties such as high toughness, residual compressive stress, hardness, and wear and corrosion resistance that are needed for specific tribo-systems. From economic and environmental points of view and due to legal limitations imposed on disposal of Cr6+ wastes from electrolytic baths and chemical compounds such as CrO3 (Environmental Protection Agency in United States), the owners of the coating industries increasingly have shown an interest in HVOF for depositing wear resistant coatings as a cost-effective process. Thermal sprayed cermet (ceramic-metal) coatings are probably subjected to different corrosion mechanisms because of microstructural properties such as porosity, cracks, types of oxide phases, and energy of the interface between metal and carbides.
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