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The aim of the research outlined in this paper is to evaluate thermal spray processes like Atmospheric Plasma Spraying (APS) for the protection and upgrade of aluminium particularly for the low cost and flexible manufacture of automotive components. A great demand for automobile fuels due to increased rate of consumption and necessity of provide clean air environment in coming years. The automobile industry not only to find alternative fuel sources but also looking for fuel economic and eco friendly vehicles. Thermal spray coatings are depositions of materials which has been melted or plasticized immediately prior to projection onto the substrate. The thermal barrier coating is done on the piston for reducing the emission and thereby improving the efficiency of the internal combustion engine. The Alumina and Silicon Carbide particle were used as coating materials and the effect of the both on the emission and mileage is reported in this paper.
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