Putting aside PTA (Plasma Transferred Arc) and Laser cladding there are only two (2) commercially viable thermal spray processes. These are: flame spraying and plasma (non-transfer) arc. Historically, knowing which coatings and their in-put raw materials, perform best in specific applications, enables the researcher to categorized the materials. Based upon known industrial applications/functions the materials can be further identified according to chemical composition. This effort is an overview of coating applications and the suitability of sprayed coatings to the functions.

Basic thermal spray coating applications and their functions may be listed as follows:
Underlayments and bond coats
Build-up and reclamation
Wear resistance
abrasive
adhesive
fretting
erosion
cavitation
Clearance control
abradable
abrasive
Thermal barrier
Environmental
high temperature oxidation and
corrosion resistance
atmospheric corrosion control
Electrical conductivity and resistivity
Biomedical
Metal and ceramic matrix composites