Abstract For protection applications in fusion devices thick TiC coatings are being developed. Coatings have been produced by plasma spraying at atmospheric pressure (APS), low pressure (LPPS) and in vacuum (VPS). Microstructural analysis of these TiC coatings includes X-ray diffraction, analysis of chemical composition, texture analysis and optical microscopy. Thermomechanical evaluation includes short-pulse laser heat flux and thermal fatigue tests, simulating plasma disruptions. The effect of thickness, porosity and microstructure is discussed.