A study of the effect of spray casting on the microstructure and properties of cold rolling mi I I work roll steels has been undertaken. Industry standard qualities have been spray formed and a corn parison of the resulting properties a nd microstructures has been made with those of the conventionally processed counterparts. The influence of process variables on the spray formed product has also been investigated. The results indicate that cold mill work roll steels which have comparable properties and structures to conventionally cast and forged products can be produced successfully in a single processing step. Furthermore, a high integrity metallurgical bond between the deposit and the substrate can be achieved.