Magnetron sputtering technique has considerable application prospects in the surface anti-corrosion aspect of automobile steel, especially Twinning Induced Plasticity (TWIP) steel. Aluminum (Al) coating is a preferred coating for TWIP steel, however, the effect of various process parameters on the corrosion resistance of Al-coated TWIP steel was not clear. In this work, hot wire plasma enhanced magnetron sputtering (PEMS) technology was used to deposit Al coatings on the surface of TWIP plate guided by the L9(33) orthogonal test design table. The three factors were hot wire current (Ih), target current (It) and substrate bias voltage (Vs), and each factor corresponded to three levels. The effects of above three factors on the corrosion resistance of Al coatings were analyzed by means of range analysis and variance analysis. The phase structure and micromorphology of Al coatings were investigated by an X-ray diffractometer (XRD) and a scanning electron microscope (SEM) respectively. The corrosion resistance of aluminum coating was tested and analyzed by an electrochemical workstation and a salt spray test chamber. The range value (R value) corresponding to Ih, It and Vs was obtained by range analysis, meanwhile, some results were also analyzed by variance analysis. The bias current density of substrate increased from 0.02 mA/cm2 to 0.72 mA/cm2 after adding Ih. But the influence of It and Vs was not obvious. The thickness of Al coatings increased from 0.67 μm to 3.16 μm with the increase of It (3 A to 9 A), however, the effects of Ih and Vs were not significant. The preferred orientation of Al coatings changed from (200) to (111) under the combined action of Ih and Vs which reflected the increase of internal stress. The SEM results showed the typical recrystallized morphologies of Al coatings. The self-corrosion potential increased from ?969 V to ?656 V with the increase of Ih, and the influence of It and Vs was small. The self-corrosion current density increased first and then decreased with Ih and It. The corrosion area was positively correlated with Ih (5.03% to 12.21%). while It acted just oppositely (10.62% to 6.51%). Therefore, hot wire current was the most significant measure of self-corrosion potential and percentage of corrosion area. The results showed the density of Al coatings was mainly affected by Ih. With Ih increased, the coatings became denser and self-corrosion potential get upper. Target current mainly affected the thickness of Al coatings. When the coating was thicker, the corrosion-resistant was better, but the coating became looser and corrosion pits increased. The substrate bias voltage had little effect on the corrosion resistance of Al coatings. In summary, the introduction of hot wire power supply has both advantages and disadvantages on the corrosion resistance of Al-coated TWIP steel sheets. As for the selection of specific process parameters in actual production, it needs to be determined by considering the target service life and specific service condition of the TWIP automobile sheet.