The deposition process of WC-Co and Cr3C2-NiCr cermet coatings through a high velocity oxyfuel (HVOF)spray process was examined using powders of different carbide particle sizes that ranged from 1.5 mm to over15 mm. The effect of carbide particle size on the thickness of flattened particles was investigated. The carbide size inthe coating was compared to that in the original feedstock. Results showed that most of the carbide particlesremained in a solid state after passing through the flame, and the deposition of the cermet coating involves lateralflattening of a solid-liquid two phase droplet rather than a single liquid droplet, as in plasma spraying of metallicand ceramic materials under optimised conditions. It was found that the size of carbide particles in a sprayed coatingdepends greatly on the corresponding carbide size in the starting powder. The large solid carbide particles in a twophase droplet tend to rebound easily during HVOF spraying when the droplet impacts on a substrate surface, whilesmall carbide particles in the droplet may follow the flattening of the liquid binder phase and be easily retained in thedeposit. Using a powder consisting of small carbide particles leads to substantial retention of carbide particles in thecoating and consequently an improved wear performance. A model is proposed to explain the effect of carbideparticle size on the splat formation by a solid-liquid two phase droplet.