Entry of global players with advanced technologies created a bottleneck competition which subsequently created a high pressure on manufacturing firms to improve the quality of their products.Automotive is one of the industries which has gone through most vigorous developments under a concrete competition scenario.Demands in automotive industries are taking up surge day by day, so all the manufacturers needed to offer high quality products with cost limitations. Since the automotive parts are to be mass produced, it is necessary that the stable supply of large quantity of materials, uniform quality, low cost/high performance are ensured.Some major problems which industry must cope with are for reduction of fuel consumption, weight reduction of component parts and reduction of friction of sliding parts.Being critical kinetic components automotive parts are always under the risks of destructive factors like corrosion, wear, abrasion & erosion. With the availability of various processes, thermal spray coating has shown a significant lowest cost/perfo?rmance ratio. Parts like shifter fork, crankshaft, valve, piston, piston ring, fuel injection nozzle, synchronisation ring etc, are treated by this coating.Shifter forks while working face problems of sliding wears, plasma sprayed dense self lubricating and wear resistance coating improves its performance and life. This coating and its processes avail automotive manu?facturers with opportunity of creating a Point-of-Difference (POP) in their components.