The Energy Sector is experiencing a critical change with the integration of AI and progressed materials. This paper investigates the part of AI in upgrading the execution of evaporator businesses, especially in thermal power plants. Different thermal spray coatings utilized in evaporator applications, such as NiCrAlY and CoNiCrAlY, are examined for their benefits in enhancing erosion resistance, wear resistance, and overall effectiveness. The potential of AI in optimizing kettle operations, foreseeing support needs, and reducing energy utilization is also analyzed. By integrating AI with advanced thermal spray coatings in the energy sector, we can achieve higher efficiency, lower emissions, and greater sustainability.