Thermal spray applications using iron based alloy powder

A wear resistant component, comprising:

• a thermal-sprayed powder metal material, wherein said thermal-sprayed powder metal material consists of 3.8 wt. % carbon, 13.0 wt. % chromium, 2.5 wt. % tungsten, 6.0 wt. % vanadium, 1.5 wt. % molybdenum, 0.2 wt. % oxygen, 70.0 to 80.0 wt. % iron, and impurities in an amount not greater than 2.0 wt. %, based on the total weight of said thermal-sprayed powder metal material.

A method of forming a wear resistant component, comprising the steps of:

• spraying a powder metal material which has been atomized and ground into atomized droplets, wherein the powder metal material comprises 3.0 to 7.0 wt. % carbon, 10.0 to 25.0 wt. % chromium, 1.0 to 5.0 wt. % tungsten, 3.5 to 7.0 wt. % vanadium, 1.0 to 5.0 wt. % molybdenum, not greater than 0.5 wt. % oxygen, and at least 40.0 wt. % iron, based on the total weight of the powder metal composition.