<p>Environmental barrier coatings (EBCs) play an important role in achieving long life service of ceramic matrix composites (CMCs) in high-temperature gas turbine application. In this paper, the detailed overview of phase and microstructural evolution of thermally sprayed EBCs has been given, with the focus on their direct contribution to the coating durability and failure modes. The effect of main process variables such as spray power, stand-off distance, feed stock composition, and substrate conditions on the crystallinity, porosity, and clustering of defects in the region is studied. It is demonstrated that the deposition conditions are not properly controlled, which results in creating amorphous phases, silicon volatilization, and mismatch-induced cracking as the significant sources of degraded EBC and its ultimate failure. A critical analysis is done in relation to the importance of substrate preheating, heat treatments, and acceptance of alternative spraying techniques such as SPS, SHVOF, and SPPS which can contribute to the improvement of coating integrity and obviate premature delamination or oxidation. Further the relevance of surface roughness and surface roughness in relation to thermal residual stresses is also stated. Lastly, machine learning algorithms in the prediction of failure-related properties (porosity, phase composition, microhardness) the next-generation art are also being introduced. This paper elaborates the importance of proper process control and material design to prevent failure in EBC systems, and it suggests that failure analysis could prove as a preemptive resource to maximize performance. The insights that have been provided could help close the gap that existed between process parameters and the failure mechanism, building a reliable EBCs to assist in future application of this turbine.</p>