Abstract:A novel vacuum melting method, which was characterized by the application of brazing foil, was proposed. With BNi-2 nickel-based brazing foil, a pre-placed CoCrW adhesive coating was melted in a vacuum furnace. The microstructure and fretting wear resistance of the coating were studied. The results showed that fully dense coating was obtained. A good metallurgical bonding was achieved not only between coating and substrate but also hard phases and bonding phases. The microstructure of the coating was composed of hard phases such as Co6W6C, Cr7C3, W2C, Ni3B, CrB and ductile phases including nickel-based and cobalt-based solid solutions. Based on the dense microstructure, the excellent metallurgical bonding and the hard phases strengthening, it is found that the fretting wear resistance of vacuum melting CoCrW coating was remarkably superior to the plasma spraying CoCrW coating and 1Crl8Ni9Ti stainless steel.