In engineering applications, the interaction between component performance, durability, and current conditions is crucial. Surface modification, like thermal spray coatings, extends component lifespans. Thermal spray coatings, including plasma spraying, are versatile and non-damaging. They enhance component strength, offering adaptability with various materials. Specifically, this study focuses on applying Tungsten Carbide as coating using the HVOF technique to enhance Aluminum 6061 components. The goals are to understand the benefits, microstructure and hardness Al6061 components in demanding engineering applications.