A compositionally complex alloy (CCA) was developed in powder form and applied as a coating onto a carbon steels substrate by using thermal spray. The purpose of this study was to investigate the effect of microstructural modification induced by using two different powder production methods, mechanical alloying and gas atomisation, onto the corrosion resistance of the coatings for a CoCrFeMo 0.85 Ni composition. The evolution of microstructure from powders to coatings was analysed using scanning electron microscopy coupled with energy-dispersive spectroscopy and X-ray diffraction. In order to evaluate the corrosion performance of the coatings, electrochemical corrosion tests were performed in a 3.5 wt % NaCl solution at pH = 4. The study demonstrates that the powder production method has a significant influence on the phase composition and, in turn, corrosion behaviour of the resulting coating, with the gas atomising route imparting better corrosion resistance properties. Nevertheless, the appearance of the face-centered cubic (FCC) phase characteristic of the CoCrFeMo 0.85 Ni alloy within the coating produced from the mechanically alloyed powder, opens the possibility for this powder manufacturing technique to effectively produce compositionally complex alloys.Coatings 2019, 9, 695 2 of 16 and consisted of Laves phase within an FCC solid solution. Elemental segregation was observed, with higher melting point elements (Cu, Nb) enriching the interdendritic regions. Better corrosion performance than previously studied coatings was measured in 3.5 wt % NaCl solution, with the Cu and Nb-rich regions representing the areas of preferential corrosion. In another work by Gao et al. [6], CCA of the CoCrFeNiAl 0.3 composition was produced by using radio frequency magnetron sputtering and tested in 3.5 wt % NaCl solution. The coatings consisted of a polycrystalline FCC structure with homogeneous element distribution and showed increased hardness and improved corrosion performance as compared to wrought 304 stainless steel. Some CCAs have demonstrated excellent performance in both H 2 SO 4 and NaCl solutions. Similar to conventional alloys, it is interesting to note that Cr, Ni, Co, Ti in CCAs enhance corrosion resistance in acid solutions, Mo tends to inhibit pitting corrosion, whereas Al and Mn display a negative effect [7]. Wang et al. [8] applied thermal spray technology to fabricate coatings of the Ni x Co 0.6 Fe 0.2 Cr y Si z AlTi 0.2 composition. Results indicated that the hardness of the CCAs prepared by using the thermal spraying in combination with annealing at 1100 • C for 10 h was significantly increased compared to that of the cast alloy. Moreover, the alloy exhibited excellent corrosion resistance, resulting from the presence of the Cr 3 Si phase and several other (unidentified) phases. More recently, the effect of grain refinement and elemental partitioning onto the strength and corrosion resistance of a friction stir processed Cu-containing CCA has been evaluated by Nene et al. [9]. Their work shows that grai...