ceramic coatings are applied on various engineering hardware components to provide protection against wear, corrosion and high heat fluxes. Metal hardware operating in harsh environments could fail prematurely due to wear, corrosion and high temperature exposure. A protective layer of coating is typically applied to provide a barrier which prolongs component durability and the desired properties of the hardware components. It is widely recognized that residual stresses in thermally sprayed coatings are highly significant in practical terms, residual stress measurements obtained using X-ray diffraction techniques are in good agreement with results obtained by neutron diffraction.