A NEW COST EFFECTIVE PLASMA SPRAY PROCESS AND SPECIALLY FORMULATED CORROSION RESISTANT MATERIALS FOR USE WITH THE PROCESS HAVE BEEN DEVELOPED. THESE MATERIALS CONSIST OF A WIDE VARIETY OF PRODUCTS BASED MOSTLY ON TRADITIONAL POLYMERS WITH THE OPTION OF ADDING FILLERS OR FIBROUS REINFORCEMENT. THIS NEWLY DEVELOPED PLASMA SPRAY TECHNOLOGY NOW PERMITS SUBSTRATES TO BE FIELD SPRAYED WITH NOMINAL HEAT INPUT.