Nanograin Fe(Al) solid solution alloy coating was firstly produced through cold-spraying technology using mechanically alloyed powder. Then, the above-mentioned coating was annealed at different temperatures to explore its influence on the phase constitution, microstructure, microhardness and dry sliding wear property of the coatings. Results exhibited that an FeAl phase appeared in the coatings after 500 °C treatment and remained stable with increasing annealing temperature. The annealing temperature had a considerable effect on the microstructure, microhardness and wear behavior of the FeAl coating. The existing laminated structure in the as-sprayed coating gradually faded away with increasing temperature and finally obtained a dense coating microstructure with no particle interface when annealed above 950 °C. Nanograin began to evidently grow at temperatures over 800 °C. The microhardness of the FeAl coating stayed at 400 Hv₀.₁ at temperatures below 800 °C, then it quickly dropped to 300 Hv₀.₁ at 950 °C and remained nearly unchangeable up to 1100 °C. The dry sliding wear mechanism of the FeAl coating annealed at low temperatures below 700 °C was mainly delamination of the oxide layer and showed a high wear rate within the order of magnitude range of 10⁻⁴, whereas FeAl coatings annealed at high temperatures above 950 °C were worn by microploughing and little oxidation and exhibited very low wear rates within the order of magnitude range of 10⁻⁶.

The influence of post-process heat treatment on cold-sprayed Zn coatings on the Mg alloy substrate was investigated at different temperatures (150, 250, and 350 °C) and times (2, 8, and 16 h). Phase, microstructure, microhardness, and tensile strength of Zn coatings were analyzed before and after heat treatment. Corrosion properties of Zn coatings after heat treatment were investigated in simulated body fluid by using potentiodynamic polarization and immersion testing. Results show that although the heat treatment presented little effect on phase compositions of Zn coatings, the full width at half maxima of the Zn phase decreased with the heat temperature and time. Zn coatings presented comparable microstructures before and after heat treatment in addition to the inter-diffusion layers, and the inter-diffusion layer was dependent on the heat temperature and time. Both the thickness and the microhardness of inter-diffusion layers were increased with the heat temperature and time, with the largest thickness of 704.1 ± 32.4 μm and the largest microhardness of 323.7 ± 104.1 HV_0.025 at 350 °C for 2 h. The microhardness of Zn coating was significantly decreased from 70.8 ± 5.6 HV_0.025 to 43.9 ± 12.5 HV_0.025, with the heat temperature from the ambient temperature to 350 °C, and was slightly decreased with the heat time at 250 °C. Although the tensile strength of Zn coating was slightly increased by heat treatment, with the highest value of 40.9 ± 3.9 MPa at 150 °C for 2 h, excessive heat temperature and time were detrimental to the tensile strength, with the lowest value of 6.6 ± 1.6 MPa at 350 °C for 2 h. The heat temperature and heat time presented limited effects on the corrosion current and corrosion ratio of the Zn coatings, and Zn coatings before and after heat treatment effectively hindered the simulated body fluid from penetrating into the substrate. The corrosion behavior of Zn coatings was discussed in terms of corrosion products and microstructures after immersion.

In the present study, a nanostructured FeAl coating was prepared by cold spraying of ball milled powder. Annealing treatment was applied to the coating to investigate its effect on the microstructure, phase structure and microhardness of the cold-sprayed nanostructured FeAl coating. The results showed that the FeAl phase was kept unchangeable when the coating annealed at the temperature above 500oC. Annealing temperature significantly influenced the microstructure and microhardness of cold-sprayed FeAl coating. With raising annealing temperature, the lamellar structure in the as-sprayed coating disappeared and a dense coating microstructure with fully bonding of deposited particles at their interfaces was achieved after annealing at 950oC. Nanograin growth of the FeAl phase occurred at an annealing temperature higher than 800oC. The microhardness of cold-sprayed FeAl coating remained about 400 Hv0.1 at the annealing temperature below 800oC and decreased to 300 Hv0.1 at 1100oC.

The study aims to enhance the corrosion resistance and bioactivity of Mg alloy substrates through the development of a zinc/hydroxyapatite multi-layer (Zn/HA-ML) coating. The Zn/HA-ML coating was prepared by depositing a cold-sprayed (CS) Zn underlayer and a high-velocity suspension flame sprayed (HVSFS) Zn/HA multi-layer and was compared with the CS Zn coating and the Zn/HA dual-layer (Zn/HA-DL) coating. Phase, microstructure, and bonding strength were examined, respectively, by X-ray diffraction, scanning electron microscopy, and tensile bonding testing. Corrosion behavior and bioactivity were investigated using potentiodynamic polarization, electrochemical impedance spectroscopy, and immersion testing. Results show that the HVSFS Zn/HA composite layers were mainly composed of Zn, HA, and ZnO and were well bonded to the substrate. The HVSFS HA upper layer on the CS Zn underlayer in the Zn/HA-DL coating exhibited microcracks due to their mismatched thermal expansion coefficient (CTE). The Zn/HA-ML coating exhibited good bonding within different layers and showed a higher bonding strength of 27.3 ± 2.3 MPa than the Zn/HA-DL coating of 20.4 ± 2.7 MPa. The CS Zn coating, Zn/HA-DL coating, and Zn/HA-ML coating decreased the corrosion current density of the Mg alloy substrate by around two–fourfold from 3.12 ± 0.75 mA/cm² to 1.41 ± 0.82mA/cm², 1.06 ± 0.31 mA/cm², and 0.88 ± 0.27 mA/cm², respectively. The Zn/HA-ML coating showed a sixfold decrease in the corrosion current density and more improvements in the corrosion resistance by twofold after an immersion time of 14 days, which was mainly attributed to newly formed apatite and corrosion by-products of Zn particles. The Zn/HA-ML coating effectively combined the advantages of the corrosion resistance of CS Zn underlayer and the bioactivity of HVSFS Zn/HA multi-layers, which proposed a low-temperature strategy for improving corrosion resistance and bioactivity for implant metals.