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Advanced HVOF-PVD duplex coatings were produced on the medium carbon steel by combinations of High Velocity Oxygen-Fuel (HVOF) and arc ion plating. The microstructures and mechanical properties were investigated by means of X-ray diffraction (XRD), scanning electron microscopy (SEM) in association with mechanical property measurement. The results show that the duplex coating are composed of an inner NiCr-Cr 3 C 2 -based HVOF-sprayed layer mainly consisted of γ-NiCr and Cr 3 C 2 phases, and an outmost PVD-AlCrN layer containing fcc-AlCrN phase. Duplex coatings reveal more excellent wear resistance when compared to the HVOF-sprayed coating. The improved wear resistance is mainly related to the outmost AlCrN layer with more excellent wear resistance in comparison to the

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