Plasma spraying-physical vapor deposition is a novel process for preparing thermal barrier coatings. The advantages of PS-PVD process were summarized, including high deposition efficiency, flexible preparation of different microstructures and excellent application of complex structural artifacts. Based on this, the test principle and process of different characterization methods were introduced briefly and the recent research progress of the characterization methods applied to PS-PVD coatings was mainly reviewed. The characterizationmethods of organizational microstructure and phase included XRD, SEM, TEM, EBSD, etc. The characterization methods of thermal protection performance included thermal insulation performance, isothermal/cyclic oxidation, thermal shock performance and hot corrosion performance. The characterization methods of mechanical properties included tensile performance, three/four-point bending test, erosion resistance and nano-indentation technique. The electrochemical characterization method called impedance spectroscopy was introduced in detail. Finally, the accuracy, convenience, objectivity and other features of different characterization methods were summarized, and some corresponding evaluations and improvement proposals were proposed based on the advantages and disadvantages of different technologies.Three key development directions of PS-PVD are prospected:convenient non-contact diagnosis methods, high-precision characterization of coating microstructures and properties and application of high-efficiency simulation technology.