This study describes the influence of the processing parameters on the structure of a Diamalloy 1008 (Fe-Cr-Mo alloy) coating applied with high velocity oxi-fuel (HVOF) on steel tool grade samples D2. This coating is commonly use as a protection against corrosion and wear, but it also has the capacity to recover damaged areas as die stamping for automotive stamp. An experimental statistic design identify the fuel velocity and oxygen flow as well as the pulverization distance as the most influential parameters that control the powder particles characteristics when it's being sprayed ("in trajectory") before impact. The effects of these parameters in porosity level, oxide content and micro-hardness were investigated in detail. Metallographic tests are used to evaluate the deposited material adhesion quality, the SEM technique is use to evaluate the material porosity in the substrate adhesion and the damage in the tools.
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