Functionally graded coatings for enhanced wear resistance in AA7075 via cold spray

•Incorporating µB4C particles reduced Al powder size by 14%.•SEM analysis confirmed uniform particle distribution in coatings.•Reinforcing particles decreased surface roughness by 47%.•Enhanced wear resistance was observed, reducing wear volume loss by 36%.•Coatings with nano-additives showed shallower wear tracks, lowering wear depth profile values by 28%. A compositionally graded, dual-reinforced aluminum metal matrix composite was applied onto the AA7075 substrate through cold spray. The coatings consisted of layers with varying compositions of 10, 15, and 20 vol% μB4C, designed to enhance wear resistance. Compositional grading of the coating extended to the top layer, which features a dual-reinforced layer comprising 2 vol% boron nitride nanotube (BNNT) and 2 vol% nB4C.