Previous work conducted by Mintek (Couperthwaite et al., 2013(Couperthwaite et al., , 2015 investigated the effect of precious metal additions on the structure, oxidation and corrosion properties of an Fe-40 at.% Al (FeAl) alloy. Initial work determined that additions of more than 0.5 at.% precious metal did not improve the oxidation and corrosion properties of the materials and in some cases even decreased the resistance to corrosion. Further work identified Pt and Ru as beneficial additions to the FeAl alloy. Four alloys were then produced by mechanical alloying and sintering (FeAl-0.2 at.% Pd, FeAl-0.2 at.% Ru, FeAl-0.5 at.% Ag, FeAl-0.5 at.% Pt). These alloys were all successfully produced by melting and casting and mechanical alloying sintering and it was found that the nonequilibrium processing greatly decreased the grain size of the materials compared to the ascast materials. It was found that the additions of Ru and Pt were still the most beneficial to the oxidation and corrosion properties, with Ru being considered the most beneficial.This report details the results from the initial spray testing work done with the FeAl-0.2 at.% Ru alloy powder produced by mechanical alloying. There are several options for powder coating onto substrates; thermalspray techniques, which include high-velocity oxy-fuel (HVOF) coating and plasma coating, or cold-spray (also known as supersonicspray) techniques. Cold-spray techniques have attracted a lot of interest lately and as a system is available at University of the Witwatersrand, it was decided to use cold spraying in the current work. This work was done to determine the effectiveness of cold-spray coating of these mechanically alloyed powders.The iron-aluminium system has attracted a large amount of research due to the fact that Fe-Al intermetallic compounds possess good mechanical properties, along with low density and low cost, as well as easy access to the raw materials (Ji et al., 2006;Montealegre et al., 2000). Arzhnikov et al. (2008) found that the Fe-Al alloys are promising, due to their good refractoriness, oxidation and corrosion resistance and good ductility at room temperature. In comparison to conventional alloys, Fe-Al alloys perform much better at higher temperatures, due to the stability of the Cold-spray coating of an Fe-40 at.% Al alloy with additions of ruthenium by R.A. Couperthwaite*, L.A. Cornish † ‡ and I.A. Mwamba* In previous work by the authors, it was established that additions of 0.2 at.% Ru to an Fe-40 at.% Al alloy improved the corrosion and oxidation resistance of the alloy. The alloy was produced by mechanical alloying and spark plasma sintering and the work showed that nonequilibrium processing was able to significantly refine the grain size of the material. The sintered material had a higher hardness than the as-cast material and the change in grain size did not significantly affect the oxidation and corrosion. In the present research, the mechanically alloyed powder was coated onto a mild steel substrate using cold-spray coating at ...