Protective coatings and methods of forming same

A substrate arranged in or on a vessel having a multi-layer protective coating resistant to impact forces and corrosion, comprising:

• a thermal sprayed bonding layer that bonds to the substrate, wherein the bonding layer is formed on and in contact with a first side of a substrate from which contamination has been removed;
• a resistance layer formed directly on and in contact with the bonding layer, wherein the resistance layer is structured to be resistant to the impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or on the vessel;
• and
• a sealant layer formed directly on and in contact with the resistance layer for sealing pores of the resistance layer.

A method of forming a multi-layer protective coating on a substrate arranged in or on a vessel, comprising the steps of:

• preparing a first substrate surface of the substrate by removing corroded surface material from the first substrate surface and roughening the first substrate surface;
• thermal spraying a bonding layer on and in contact with the first substrate surface;
• forming a resistance layer on and in contact with the bonding layer, the resistance layer being resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or one the vessel and comprising at least one of an iron-based alloy and a nickel-based alloy;
• and
• forming a sealant layer on and in contact with the resistance layer, wherein the sealant layer penetrates pores of the resistance layer.