The Protal process combines surface preparation using a laser and thermal spraying in one production step. The laser preparation is based on a photomechanical reaction induced by the interaction between a laser of high instantaneous power and a polluted surface. The mechanism of bonding and the coating-substrate interface are then changed in comparison with grit blasting resulting in a significantly reduced substrate roughness. This study is aimed at finding the optimal Protal process parameters for the coating adhesion of a Ni5%Al sprayed on Ti6Al4V and IN718 alloys. The parameters investigated are laser beam intensity, the time delay between the laser impact and the spray impact, powder feed rate, substrate roughness and temperature. A test plan including these parameters is analysed by means of a fractional factorial design of experiment method. The adhesions of the coatings are measured using the ASTM C633 standard test. Data are analysed by a multiple linear regression model using a least squares fit. In addition, the coating/substrate interface is examined by optical and electron scanning microscopy (SEM) techniques as well as by Auger electron spectroscopy. Substrate roughness, substrate temperature and laser intensity are all shown to have a negative correlation with adhesion strength within the investigated range. Areas of diffusion are noticed at the coating/substrate interface.