The aim of this work was to develop a new coating material based on Ni20Cr alloy modified with up to 50%wt. rhenium. The modification was carried out by the mechanical mixing of the base powder and ammonium perrhenate with the subsequent thermoreduction in an H₂ atmosphere. The obtained powder consists of a nickel–chromium core surrounded by a rhenium shell. The characterization of the powders—including their microstructure, phase and chemical composition, density, flowability, particle size distribution, and specific surface area—was performed. The influence of plasma current intensity and hydrogen gas flow on in-flight particle temperature and velocity were investigated. The results indicate that there is interdiffusion between the base Ni20Cr and the rhenium shell, resulting in intermediary solid solution(s). The modified powders have a higher specific surface area and a lower flowability, but this does not prevent them from being used as feedstock in plasma spraying. In-flight measurements reveal that increasing the content of rhenium allows for the higher temperature of particles, though it also reduces their speed.

Implementation of novel antiviral coatings and textiles, which can be utilised in the production of personal protective equipment, has the potential to enhance public health security against future pandemic outbreaks. Respiratory viruses, particularly SARS-CoV-2, responsible for COVID-19, have emerged as a major global concern due to their rapid transmission and high mortality rates, leading to nearly seven million deaths worldwide between 2020 and 2025. This statistic underscores the necessity for the development and implementation of advanced antiviral materials to prevent viral infections. This research focused on the in vitro evaluation of the antiviral properties of three antibacterial compounds containing silver (Ag) that were functionalized with coatings. We assessed onsite synthesised Ag powder in comparison to commercially available antibacterial additives, which included nanosilver on colloidal silica (AgSiO₂) and silver sodium hydrogen zirconium phosphate (AgNaOPZr), as potential antiviral agents in coatings against human coronavirus (HCoV). Antiviral assessments revealed that coatings containing Ag at higher concentrations (2.5 and 5%) exhibited limited antiviral effectiveness, with a titer reduction in log < 2. In contrast, the functionalization of AgSiO₂ on coatings significantly suppressed viral replication resulting in a notable reduction in virus titer of log ≥ 2 for all tested concentrations.