To date, chrome plating is used as a wear enhancer for many industrial as well as military systems. However, the chromic acid used in the deposition process contains hexavallent chromium, a know carcinogen and toxic substance. The waste disposal process is very expensive. This paper presents the alternative coating materials as well as process development to achieve these coating. High Velocity Oxyfuel process is utilized to deposit cermets and refractory materials such as Ta, Re and Mo. The necessary process development for coating the inside surface of barrels will also be discussed. The effect of process variables such as fuel type and the combustion parameters on coating quality will be presented. The cost effectiveness and manufacturability of the replacement coatings compared to currently used chrome plating will be addressed.