An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process associated with a plurality of process attributes. The example system includes a computing device including an acoustic data signal module and a control module. The acoustic data signal processing module may transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum. The control module may determine a process attribute of the plurality of process attributes that deviates from a predetermined operating range by identifying at least one characteristic of the frequency-domain spectrum, selecting at least one component of the thermal spray system based on the process attribute, and controlling the thermal spray system to adjust the process attribute toward the predetermined operating range by sending a control signal to the at least one component.