Corrosion costs for U.S. Army vehicles, in both monetary and mission readiness terms, are substantial. The Army's Corrosion Measurement and Control Program was initiated in 2000 to investigate ways to extend the life of vehicle components beyond 20 years. This paper reports on the
corrosion resistance of sacrificial aluminum coatings applied by arc spray, wire flame spray, and high velocity particle consolidation spray metal techniques. These three spray techniques have advantages
when used for corrosion prevention. This paper presents preliminary results of electrochemical and electron/optical microscopy investigations of the sprayed aluminum coatings on steel substrates.