Thermal spray methods have grown in popularity across various sectors due to their ability to deposit protective coatings on surfaces. These coatings improve the surface qualities of substrates, including resistance to wear, corrosion, and thermal insulation. However, a number of crucial elements impact the quality and function of the coated substrate surface. This chapter provides a thorough evaluation and effects of significant factors on the coated substrate surface using a range of thermal spray techniques. Powder characteristics, process parameters, substrate preparation, and post-treatment techniques are some of these crucial elements. The effects of several factors, such as powder characteristics, process parameters, substrate preparation, and post-treatment processes, are explored in relation to the coating's microstructure, adhesion, and overall performance. The objective of this study is to examine the effects of various factors influencing the coated substrate’s surface and to provide suggestions for future investigations aimed at improving thermal spray methods.