Typical industrial market and turbine requirements are based on both technological and economic considerations which include the actual processing costs. This paper compares and contrasts the technical and economic aspects of spraying tungsten carbide (12%Co, 17%Co and CoCr) and MCrAlY materials using both gaseous and liquid HVOF systems. Resulting coatings have been evaluated based on metallography, micro and macrohardnesses, rubber wheel wear and surface finishing characteristics. The results of deposition efficiency and the resulting spray economics are reviewed and discussed.