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We report the results of the influence of acetylene and oxygen gas pressure on the corrosion resistance of bronze–aluminum coatings deposited on a naval brass substrate by means of the thermal (flame) deposition process. The coatings were characterized by means of scanning electronic microscopy (SEM), energy-dispersive X-ray spectrometry (EDS), X-ray diffraction (XRD), X-ray fluorescence (XRF), and transmission electron microscopy (TEM). The corrosion tests were carried out via Tafel and electrochemical impedance spectroscopy (EIS). In addition, some samples were selected in order to investigate heat treatment and its effects on corrosion resistance. The results indicate that changes in the pressure and flow of the gas affects the composition, morphology, and physical properties of the coatings, and these effects have consequences for the behavior of the coatings when they are immersed in corrosion environments. The collision speed of the particles was identified as the most significant factor that influences the properties and the performance of the coating. The gas pressure modified the oxides and the porosity level, which improved the corrosion resistance.

The Corrosion Resistance of Aluminum–Bronze Coatings as a Function of Gas Pressure Used in the Thermal Spraying Process