Phosphating and anodization for improved connection of a thermally sprayed coating on motor cylinder bores

A cylinder bore of the engine with an anodized or phosphated bond coating and a method of surface coating a cylinder bore of the engine with an anodized or phosphated bond coat prior to depositing a thermospray protective layer. Cleaning methods or related pre-treatment operations can also be used. In a preferred form, the cylinder bore of an aluminum-based alloy or a magnesium-based alloy, while the bond coating comprises a porous interface between the cylinder bore and the outermost protective layer. Additives in the anodizing or phosphating can be added to promote adhesion and corrosion resistance.