AbstractThe combined use of metal spraying and painting to enhance the corrosion resistance of steel has been studied. Zinc, aluminium, and 85 Zn-15 Al layers,∼100μm in thickness, were sprayed on to steel substrates. Chlorinated rubber, acrylic, and epoxy resin paints were then applied to a thickness of 50-100μm on the metal sprayed layers. The corrosion resistance was assessed using an accelerated deterioration test in which test samples were exposed to cycles consisting of 1h UV irradiation at 40°C followed by immersion for 1h in 3%NaCI solution. Bending and salt spray tests were also conducted. Corrosion resistance was found not to depend on the bending angle of the testpieces, but only on the character of the sprayed metallic layers. However, the paint overcoats did show some cracking after bending, suggesting that salt spray testing after bending is an effective means of evaluating the comformability of sprayed metal and paint coatings. It is concluded that paint overcoats on sprayed metal layers improve the corrosion resistance of steel considerably.