Coating deposition on many industrial components with good microstructural, mechanical properties and better wear resistance is always a challenge for the thermal spray community. A number of thermal spray methods are used to develop such promising coatings for many industrial applications; viz. arc spray, flame spray, plasma, and HVOF. All these processes have their own limitations to achieve porous free, very dense, high performance wear resistant coatings.

In this study, an attempt has been made to overcome this limitation. Molybdenum coatings were deposited on steel substrates using Wire flame. As-sprayed coatings were analyzed for phase using x-ray diffraction (XRD), and for microstructural using scanning electron microscopy (SEM), also the microhardness of coatings are measured. Results show that the coatings have good performance in terms of microstructural, mechanical and wear resistance properties.