Method of making powder for thermal spray application

This patent describes a method for preparing an intimate mixture of powders of nickel-chromium-boron-silicon alloy, molybdenum metal powder, and chromium carbide/nichrome alloy suitable for thermal spray coatings. It comprises milling a starting mixture of the nickel-chromium-boron-silicon alloy, molybdenum powder, and the chromium carbide/nichrome alloy to produce a milled mixture wherein the average particle size is less than about 10 micro-meters in diameter; forming an aqueous slurry of the resulting milled mixture and a binder selected from the group consisting of an ammoniacal molybdate compound and polyvinyl alcohol and agglomerating the milled mixture and the binder to produce the intimate mixture