Characterization of thermal flame sprayed coatings prepared from FeCr mechanically milled powder

► To improve XC 38 steel properties FeCr thermal spray coatings were elaborated using mechanical milled powder. ► Effects of surface roughness and coating thickness were reported. ► The average porosity level for the specimens is about 3%. ► The thinner coatings show the best mechanical and electrochemical properties. ► The chromium concentration increases with decrease of coating thickness. ► Using bond layer and voids sealing treatment reduce NaCl penetration.