This paper describes recent effort to synthesize Fe-based amorphous alloys coatings using Cold Gas Dynamic Spraying. Characterization of the gas atomized Fe-based (Fe-Cr-Mo-WC-Mn-Si-Zr-B) powder shows that fully amorphous powder is found when particle diameter is below 20 µm. The coatings produced were composed of the same microstructure as the one observed in the feedstock powder. The overall deformation suggests the occurrence of a localized deformation process at the particle/particle boundary and possible adiabatic deformation softening inside the powder particles during splat formation. The influence of the substrate material on the coating deposition process was also investigated. The synthesis of fully amorphous, porous free coatings using Cold Spray was demonstrated in this work.

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