Thermal spray coating was studied as one of the techniques used for coating graphite reinforced polymer composites, which are extensively used in the aviation industry. These coatings were studied for improvement of surface properties such as erosion resistance, UV protection, hardness and electro magnetic shielding. NiAl (65%Ni,35%Al) intermetallic, NiAl (95%Ni,5%Al), Aluminum and Zinc coating were thermal-spray deposited using different procedures (plasma, flame, electric wire arc) onto polymer composite substrate. Two categories of coating were evaluated: Coatings with bond coat and coatings without bond coat. Different levels of pre-surface preparation for thermal spray coatings were also studied. The microstructures, micro-hardness and electrical conductivity of these coatings were determined. Effect of different parameters on coating properties like micro-hardness and electrical conductivity were studied. / Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Mechanical Engineering / "December 2006."