The coating layer of Fe–Al powders on the steel substrate was prepared by mechanical alloying at room temperature. Fe, Al, and the steel substrates were milled with high-energy ball milling for 32 h with a ball-to-powder ratio of 8 in an argon atmosphere to prevent oxidation during milling. Although mechanical alloying was performed for 32 h, no new phases were observed after mechanical alloying, as analyzed by X-ray diffraction. However, the crystallite size of the milled powders for 32 h decreased by factor two compared with the initial powders. Scanning electron micrographs showed that the coating layers formed >8 h after mechanical alloying. The intermetallic Fe3Al formed after the substrate was annealed at 500 ℃.
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