The melting conditions of the electrode wires and the structure of coatings, obtained by the electric arc spraying method depending on the pressure of the spraying air flow, are analysed in the current paper. The effect of air pressure on the spraying angle of the flow of melted metal droplets is demonstrated. It is established that due to the decrease in this spraying angle, the temperature of the droplets increases. In addition, high-speed airflow is more easily captured by smaller molten metal droplets and during the contact with the substrate surface their deformations were more strongly. Due to such phenomenon, the porosity of the coatings was reduced and the number of lamellae, welded to each other, increased. With the increasing pressure of the air flow, the thicknesses of the lamellae were decreased, however, the amount of the oxide phase in the coatings has increased. As a result, the hardness, wear resistance and cohesive strength of the coatings, obtained at a higher pressure of the air flow, have increased, and the level of residual stresses of the first kind in them decreased.
A wear proof layer was obtained by applying vibration with a frequency of 100 Hz and amplitude of 0; 70; 300 μm to the cored wire of Fe-Cr-B-C doping system during welding. It was shown that horizontal vibration affects the grinding process of boride inclusions: their average diameter reduces from 175 to 5 μm, and the amount of (FeCr)2B plastic phases increases during the redistribution of phases. Wear resistance of the metal, which was deposited using horizontal vibration with an amplitude of 300 μm, increases by 2.3-2.5 times due to wear with the fixed and unfixed abrasive material, and by 2.8 times due to wear under impact loads. For restoration and strengthening of large-size parts, it is proposed to add Al-Mg powder (Al = 47 - 53 %, Mg = 53-47% wt. %) to the CW charge to increase wear resistance of the deposited metal of the Fe-Cr-B-C system. This contributes to the dispersion of the boride inclusions, the average diameter of which decreases from 70 to 5 μm. In the structure of the deposited metal of the Fe-Cr-B-C system, inclusions of the complex alloyed nitrides are extricated with an average size less than 1.0 μm. As a result, the average value of microhardness increases from 700 to 900 HV. Wear resistance of the deposited metal increases by 1.5 times due to wear with the fixed and unfixed abrasive material, and by 2.0 times due to wear under impact loads.