Functional coatings are widely used in energy generation equipment in industries such as renewables, oil and gas, propulsion engines, and gas turbines. Intelligent thermal spray processing is vital in many of these areas for efficient manufacturing. Advanced thermal spray coating applications include thermal management, wear, oxidation, corrosion resistance, sealing systems, vibration and sound absorbance, and component repair. This paper reviews the current status of materials, equipment, processing, and propertiesÕ aspects for key coatings in the energy industry, especially the developments in large-scale gas turbines. In addition to the most recent industrial advances in thermal spray technologies, future technical needs are also highlighted.