The work aims to improve wear resistance by optimizing coating preparation process and preparing dense Fe-based amorphous alloy coatings. Dense Fe-based amorphous alloy coatings were fabricated by adopting activated combustion high velocity air fuel (AC-HAVF) technology and optimizing process. Microstructure, tribological properties and wear mechanisms of the as-sprayed coatings were thoroughly analyzed with scanning electron microscope (SEM), X-ray diffractometer (XRD), vickers microhardness tester, friction and wear tester, 3D optical profiler, etc. The microstructure of Fe-based amorphous alloy coatings presented amorphous structure. The thickness of as-sprayed coatings was nearly 300 μm. Average microhardness of the coatings was up to 1000HV0.1. Moreover, wear mass loss of the Fe-based amorphous alloy coatings was far lower than that of 304 stainless steel. Wear rate of the Fe-based amorphous alloy coatings was 1/3～1/2 of 304 stainless steel substrate. The wear mechanism of Fe-based amorphous alloy coatings was mainly fatigue wear, accompanied by oxidation wear. Oxidation wear was mainly caused by friction heat generated during dry sliding process, which accelerated delamination of the coatings. Lower porosity and higher amorphous content of Fe-based amorphous alloy coatings help to improve wear resistance and stabilize friction coefficient.