An Fe-based coating was thermally sprayed onto the surface of AZ91 magnesium alloy via High-Velocity-Oxygen-Fuel (HVOF) method. The with a thickness 530 ± 25 µm and porosity 0.7 0.1% did not show any macrostructural defects cause degradation alloy. Laser remelting layer resulted in recrystallization structure disappearance presented pores, splat boundaries, other defects. This led to an increas...