Burnishing as a novel approach can be employed in this research study to reduce the porosity of thermal spray coating. The configuration of coatings is established according to the character they have to perform in various material systems and environments" (Hocking 1993). The coatings are likely to develop gradually escalating protective oxides preventing the diffusion of corrosive species towards the coating. These protective oxides should possess good resistance against sputtering or spallation due to thermal and mechanical stresses induced while working on the components. Moreover, the applied coatings also act as a "reservoir" for the constituents forming the protective surface oxides(Gurrappa 2003) (Injeti 2008) (Hocking 1993). This study aims at studying the effect of burnishing on thermal spray coatings against high-temperature aggressive environmental applications of boilers, gas turbines, and waste to energy plants, etc. The Burnishing process is used to achieve a high surface finish on metals resulting in a smooth hardened surface with some improved mechanical properties (Vinitha and Rao 2012).