Fabrication and corrosion resistance of HVOF-sprayed Ni2Si intermetallic compound

► Ni2Si intermetallic coatings were produced by HVOF spraying. ► A bulk Ni2Si was used as a reference for corrosion tests in 70% H2SO4. ► Corrosion rate of HVOF coatings was much lower than that of substrate. ► Both HVOF Ni2Si and bulk Ni2Si showed active-passive behavior. ► There was a small performance gap between coating and reference material.