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Current WC-Co cemented carbide coatings are mainly prepared by micro-size powders. In the present work, the ultrafine WC-Co composite powder was rapidly synthesized by the technique of in situ reactions. By controlling the carbon addition of the raw powders as 17.04% in mass fraction, the as-synthesized ultrafine WC-12Co composite powder only contains WC and Co phases, with an average particle size of 210 nm. The ultrafine structured WC-12Co cemented carbide coating was fabricated by the high velocity oxy-fuel method, using the agglomerated and sintered composite powder particles. The results indicate that the coating fabricated by the ultrafine composite powder has obviously lower porosity, 30% higher hardness as up to 1300HV0.3, and better wear resistance especially in larger load than those of the coating fabricated by conventional commercial powder. The results demonstrate that the ultrafine WC-Co composite powder has superior advantages in preparing cemented carbide coatings with high performance.
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