The cathodic protection has been widely adopted as the more effective protection technique in a marine environment. Thermal spray coating technology is a kind of sacrificial-anode cathodic protection method, since differences in the electrical potential of materials are employed. If a base metal (STS304) is exposed to seawater owing to a defect in the thermal spray coating, the base metal is protected by the sacrificial anodic characteristics of the coating layer. This is because a micro-cell is formed by the base metal and the thermal spray coating layer that respectively act as the cathode and anode electrochemically. As regards optimal spray distance, surface morphology was not found to make a great difference, but a spray distance of 80 mm seemed to give a dense coating. Clear differences in the thickness of the coating were observed in cross-sections, which verified that with increased spray distance there was more porosity in the coating layer resulting from oxygen and impurities in the air.

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