Laboratory and field test data have proven that HVOF chrome carbide coatings outperform hard chrome plating in tribocorrosion applications such as hydraulic cylinder rods by 2x or more. Although this enormous technical advantage and environmental benefit, replacing Cr plating with HVOF coating in OEMs still faces huge economical obstacle due to the relative high cost of HVOF coating. In an effort to bring the HVOF coating cost down to chrome plating level, new chrome carbide/NiCr type of composite powders were developed at Caterpillar. They offer 30~40% cost reduction in comparison with powders of similar performance in the market. Lab tests show that powders have good flowability and spraybility. Coatings made from the powders possess superior wear and corrosion resistance. Technical result is reported in detail.