Materials resulting from thermal spray processes are often different from their wrought, forged, and cast counterparts. Assessing the usefulness of thermal spray coatings requires understanding, developing, and using appropriate testing and characterization methods that are generally borrowed from other materials science disciplines. This article focuses on commonly used testing and characterization methods: metallography, image analysis, hardness, tensile adhesion testing, corrosion testing, x-ray diffraction, non-destructive testing, and powder characterization. It provides information on how the materials themselves respond to the various test methods. The article focuses on the test methods themselves, including those test parameters that can be varied and...