Erosion-corrosion of thermally sprayed coatings in simulated splash zone

► Erosion-corrosion experiments were carried out on self-made device by simulating the splash zone working environment of marine structures. 8 samples can be evaluated simultaneously, and the impact frequency and velocity of water jet can be adjusted and controlled. ► There were mainly a large number of pits with varying depths and even cracks in the zones impinged directly by the water jet, while streamlined morphology with black rust appeared in the other zones. The erosion environment of samples is well consistent with the actual splash zone where there objectively exists a direct impact of wave then washing own the surface of marine structure. ► The erosion morphology of sealed Al/Ti coating suggests that vacuoles collapse play a key role in the failure process of coatings in simulated splash zone. ► The erosion resistance of Al/Ti coating is the worst among the four kinds of coatings, and this result is in agreement with its poor ability to withstand micro-jet cutting. Therefore, micro-cutting of water jet is the main factor that cause erosion failure, and appropriately increasing the plastic deformation capacity of the coating will help to improve their corrosion resistance in the splash zone.