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The finer points that contribute to top quality results at an effective cost will be considered. There are many factors that contribute to the quality aspects of thermal spray surfaces. The surface preparation with cleaning and degreasing is one critical process to be performed with care. The spray gun and the adjustable variables，such as type of gas and flow rate are usually considered. Fusing parameters are defined when lower porosity is required. The correct metal powder consumable is another point. The alloy choice is often based on the final hardness required for the application. The particle size interval is defined based on the spray technique and the equipment manufacturer’s recommendations. The combination of all these points will contribute to the quality aspects of the final coating surface. However，this is not sufficient when one strives for the best. This paper will consider other factors such as morphology. This influences not just the productivity and gas volumes but also the smoothness of flow that contributes to more even surfaces.