The in-service failure of components fabricated in engineering steels due to corrosion by aqueous solutions (acidic, alkaline, saline etc.) is a major problem in a number of key European industrial sectors (e.g. petrochemical, chemical, offshore, pulp & paper and power generation). The replacement and repair of components in these industries is costly in terms of materials, parts and shutdown time, costing typically 2.5-5.0 % of the GDP of most countries. In industrial applications where corrosion has been identified as a major contributing factor to component failure, corrosion resistant alloys (CRA) coatings have traditionally been deposited by the arc welding processes. The objective of this programme is to demonstrate that the requirement for a metallurgically bonded coating system, can be replaced by mechanically bonded thermally sprayed coatings deposited by high velocity oxy-fuel (HVOF) spraying. In addition, it is proposed to demonstrate that standard HVOF coating thicknesses (0.2 mm) can provide superior corrosion resistance to their thicker weld overlay counterparts (> 2 mm). The HVOF technology is already well-established amongst European SMEs, principally as sub-contractors to the aerospace and petrochemical industries for the deposition of wear resistant (tungsten carbide based) coatings. An opportunity exists for European SMEs to expand the use of the HVOF technology into new, and potentially much larger industrial world markets.