The optimum conditions for various thermal spray methods used to protect ship and marine structures in a seawater environment were investigated from the viewpoint of microstructure and electrochemical methods. This study investigated the corrosion protection characteristics of Zn, Al, and Zn-15%Al spray coatings for STS 304. If STS 304 is exposed to seawater owing to a defect such as porosity or an oxide layer, the STS 304 and the thermal spray coating materials act as an anode and cathode, respectively. Tafel analysis showed that the corrosion current densities of STS 304 and with Zn, Al, and Zn-15%Al thermal spray coatings were 7ⅹ10^-7, 2.4ⅹ10^-5, 7ⅹ10^-6, and 1ⅹ10^-5 A/cm² respectively. The corrosion current densities recorded in the Tafel experiment were lowest in Al-coated specimens. In the galvanic cell that is formed by the thermal spray coating layer and STS304, the corrosion protection characteristics and the lifetime of the thermal spray coating layer were estimated, as the corrosion potential decreases with increasing corrosion current density.

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