Today, the manufacture of components with improved functionality and performance for industrial applications involves not only the selection of better and lighter materials but also the use of surface engineering to achieve superior resistance-to-weight ratio. For applications in aeronautical and aerospace sectors, friction, wear, temperature resistance, erosion, corrosion, adhesion, and surface finishing are some aspects of interest in research. The technique used for coating any substrate strictly depends on the type of material and the property that is required to improve. Nowadays, thermal spraying is a reliable and cost-efficient method to deposit thick coatings with a wide variety of feedstock materials and substrates. This chapter presents a review of the main thermal spray processes used to coat light alloys and shows experimental results of AlSiC and FeCrBSiNbW alloy coatings deposited on the 6061-T6 aluminum alloy. Splat formation and microstructure, including solid-liquid two-phase droplet impacting the coating deposition, are reviewed.