Surface engineering to improve the wear resistance of surfaces is revi
ewed. Advances in powder production, process control and modeling as w
ell as application techniques are described Determination of the appro
priate thermal spray coating and spray process. industries and typical
components requiring these coatings are discussed. The various wear p
rocesses and coatings used to counter wear are briefly reviewed. The G
ator-Gard (registered trademark) plasma spray process is reviewed alon
g with its utilization in applying several types of protective wear co
atings for various aerospace and industrial applications.