INTRODUCTION 
Thermal sprayed metal coatings have been proven to provide superior long term corrosion protection in a variety of environments in programs sponsored by the Federal Highway Administration (FHWA), National Association of Corrosion Engineers (NACE) and the U.S. Navy (USN). This process has been used since the early 1900's and exposure tests have proved them superior to paint coatings. Various thermal spray coatings have been used to protect and/or reclaim metal surfaces from the following types of metal wear:
Abrasion - Loss of material from a surface by means of some mechanical action.

Corrosion - Partial or complete wearing away, dissolving, or softening of any substance by chemical or electrochemical reaction with its environment. The gradual action of natural air or salt water, on metals.

Cavitation - A form of erosion causing material to be removed by the action of vapor bubbles in a very active liquid.

Erosion - The removal of material from a surface due to mechanical interaction between the substrate surface and a fluid(s) or solid particles

Fatigue - Wear of a solid surface caused by fractures arising from material fatigue.