In this study, aluminum alloy Al-5Fe-V-Si (in wt.%) feedstock powder, produced by rapid solidification (RS) using the gas atomization process, was selected to produce high-temperature resistant Al-alloy coatings using the cold gas dynamic spraying process (CGDS). The alloy composition was chosen for its mechanical properties at elevated temperature for potential applications in internal-combustion (IC) engines. The CGDS spray process was selected due to its relatively low operating temperature, thus preventing significant heating of the particles during spraying and as such allowing the original phases of the feedstock powder to be preserved within the coatings. The microstructure and phases stability was investigated by means of Scanning Electron Microscopy, transmission electron microscopy, X-ray diffraction and differential scanning calorimetery techniques. The coatings mechanical properties were evaluated through bond strength and microhardness testing. The study revealed the conservation of the complex microstructure of the rapid solidified powder during the spray process. Four distinct microstructures were observed as well as two different phases, namely a Al13(Fe,V)3Si silicide phase and a metastable (Al,Si)x(Fe,V) Micro-quasicrystalline Icosahedral (MI) phase. Aging of the coating samples was performed and confirmed that the phase transformation of the metastable phases and coarsening of the nanosized precipitates will occurs at around 400 °C. The metastable MI phase was determined to be thermally stable up to 390 °C, after which a phase transformation to silicide starts to occur.
