Inconel thermal spray coatings are potential candidates for wide industrial applications. However, the coating structure resulting from thermal spray processes characterized by unmelted particles, oxides and porosity can severely hinder their corrosion resistance in aggressive media. The aim of the present work was to optimize elaboration parameters in order to enhance their chemical stability. Electrochemical criteria were used to identify the ability of those coatings to form a passive film in a sulfuric acid solution and also to determine their local corrosion resistance in a chloride solution. Results show that the passivity state is strongly conditioned by the coating microstructure. Coatings free of unmelted particles exhibit a notably reduced passive current density while the localized corrosion resistance seems conditionned by the amount of interlamellar oxide.

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