The working life of a variety of large machine components can be extended by the use of alloy spray coating technology. This is applied in two main ways; Fabrication of parts to smaller specification than required, then application of alloy coating to give higher materials performance at surface compared with the bulk material Rebuilding of worn surfaces on used parts to original specification The composition of the spray alloy is adjusted to give the desired combination of wear and corrosion resistance. For alloy materiais. these properties are to some extent mutually exclusive. In most engineering applications, wear resistance is required over corrosion resistance, and the spray alloys are optimised for this property. However. for the food and chemical process industries, an equivalent stress is placed upon corrosion resistance, Spray alloys developed for these applications therefore represent a compromise of wear and corrosion resistance, with limited performance for both materials properties. There is therefore a need for innovative materials research and development to widen the number of alloy composition variables in order to allow maximum performance in both wear and corrosion resistance. This project will specify optimal compositions of Ni/Cr spray coating alloys for use in a number of representative end user applications. The central aim will be to increase the working life in terms of both wear and corrosion resistance, but at reasonab!e cost. It will also be necessary to develop the spray fusing techniques already in common use for the application of the new alloy compositions.