Abstract: A new developed CO₂ arc welding-spray powder muti surface method was used to study the effect of powder feed rate and airflow rate on the hardness and abrasion performance of the deposited metal by spraying high-carbon chromium iron powder. The microstructure and phase of the deposited metal were studied by XRD and TEM method. The results show that the hardness can reach 55 HRC when the powder feed rate is 800 g/h and the airflow rate is 5 L/min. The abrasion performance of the deposited metal by spraying high-carbon chromium iron powder is four times than that by only using the H08Mn2Si welding wire. Spraying high-carbon chromium iron powder will increase the cooling rate of molten pool and accelerate the production of the non-equilibrium microstructure including large amount of dislocation entanglements, the crack and distortion of the lath martensite and the irregular configuration twin-martensite. The sprayed high-carbon chromium iron powder could act as the nucleation particles to make the weld grain size finer. The abrasion performance of the deposited metal was improved for the creation of the chrome carbide.