Abstract: In this study, microstructure and magnetic properties of FeNb coatings produced by HVOF thermal spraying were investigated. The as-sprayed coatings were annealed at the temperature of 800°C for 30 min. The results showed that FeNb coatings have nonmagnetic structure. After crystallization by heat treatment, the magnetic properties of the FeNb were weakly improved. Predicted results show that spray distance and fuel flow modified the deposit porosity. A decrease resulted in improvement of coercivity and saturation magnetization.