HPCS processing is a solid-state, additive manufacturing method of developing coatings with fine microstructures, high tensile strength and adhesion, superior wear performance, and tailorable anodic or cathodic corrosion protection. In structural applications, steel is often exposed to aggressive atmospheric conditions, which frequently occurs in highly polluted areas or near saltwater, causing higher corrosion rates than experienced in rural environments. Damage to critical structural members over time is unavoidable, due to any number of anticipated or unanticipated loading and environmental conditions. Conventional modes of repair, such as welding, often introduce additional problems, such as cracking caused by high tensile residual stresses at inherent discontinuities in the weld, corrosion sensitized areas adjacent to the weld repair, and weakening of the surrounding material from the heat input. In this ongoing work, HPCS coating is being optimized for corrosion and wear protection of structural steel, specifically targeting 1084 and R236 railway steel, using nitrogen.