This paper investigates the effect of arc spraying power on the microstructure and mechanical properties of Zn-Al coatings deposited on carbon fiber reinforced epoxy composites (CFRE composites). The bond strength between the Zn-Al coatings and the substrates was tested on a RGD-5 tensile testing machine. The microstructures and phase composition of the as-sprayed coatings were examined by scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively. The results showed that both the melting extent of Zn-Al particles and the bond strength of the coatings were evidently improved by increasing the spraying power. Moreover, the content of crystalline Zn-Al coatings was slightly changed. Observation of fracture surfaces showed that the Zn-Al coatings could bond well with the carbon fiber bundles using 40 kW spraying power. (C) 2010 Elsevier B. V. All rights reserved.