In-situ plasma spraying (IPS) is a promising process to fabricate composite coatings with in-situ formed thermodynamically stable phases. In the present study, mechanically alloyed Al–12Si and SiO2 powder was deposited onto an aluminum substrate by atmospheric plasma spraying (APS) to obtain a composite coating consist of in-situ formed alumina reinforced hypereutectic Al-18Si matrix alloy. The effect of arc current on the corrosion behavior of the composite coating has been investigated. Corrosion resistance of the composite coatings was analyzed by using the potentiodynamic polarization scanning (PDS) technique. Surface morphology of the coatings before and after the corrosion test was examined by using metallographic methods and scanning electron microscopy (SEM). Obtained results are discussed in detail.

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