A　novel　alumina-assisted　treatment　process　was　proposed　to　manufacture　fully　densified　and　perfectly　spherical　WC-Co　particles　for　thermal　spraying　applications.　In　as-sprayed　coating,　the　decarburization　phenomenon　common　in　previous　studies　was　almost　entirely　eliminated,　and　a　unique　binder　structure　with　nanocrystalline　and　amorphous　Co　co-existing　was　obtained.　Owing　to　the　strengthening　effects　of　nanocrystalline　Co　and　WC/Co　interfacial　bonding,　the　wear　resistance　of　the　new　coating　was　4　times　higher　than　that　of　the　conventional　coating　prepared　with　a　porous　feedstock.　Instead　of　plastic　deformation,　interface　fracture　and　micro-cutting　that　mainly　occurred　in　conventional　WC-based　coatings,　fracture　of　WC　grains　and　subsequent　oxidation　dominated　wear　failure　of　the　new　WC-Co　coating.　The　present　work　opens　up　new　opportunities　for　the　fabrication　of　dense　ceramic-metal　composite　particles　and　wear-resistance　enhancement　of　cermet　coatings.　(C)　2020　The　Authors.　Published　by　Elsevier　Ltd.