Arc spraying has always been the most cost-effective way of thermal spraying metal alloys but oxide content and degradation of the alloy by loss of particular alloying elements have limited quality of the coatings. In this paper a process is described which greatly reduces degradation and improves coating density and oxide content. Corrosion behaviour both in aqueous and high temperature environments is markedly improved. For aqueous applications coatings of Inconel 625 were tested in a potentio-dynamic cell and by salt spray testing to evaluate both the inherent properties and the permeability of the coating and significantly improved behaviour was found in both cases. For high temperature corrosion, samples of FeCrAl were tested in air and in a sulphidising environment with and without thermal cycling. Coatings of NiCrAl and NiCrTi were also examined. The coating types and test regimes were aimed at specific practical applications such as fireside corrosion in boilers and waste incinerators, hot oxidation of flare stack burners etc. In the aqueous situation valves and process vessels are being examined as candidate applications for Inconel 625 coatings.