Recent innovations in equipment, processes, and diagnostics make thermal spray coatings both practical and desirable for use in large scale automotive manufacturing.The advent of rotating devices and surface preparation methodologies such as high pressure water jet, electrodischarge machining, and chemical fluxes permit thermal spray coating applications on cylinder bore and valve seat areas of engines. Low carbon steel alloy composite and aluminium bronze coatings have been successfully tested on cylinder bores. The Fe–Fe3O4/Ni–NiO–CrO composite coating obtained by spraying carbon steel and nickel base alloy wires using a two wire arc gun works well as a valve seat material.