A protective coating system for metal components includes a superalloy metal substrate, such as a component of a gas turbine. A single layer bond coat is applied to the superalloy metal substrate in a thermal spray process from a homogeneous powder composition having a particle size distribution wherein about 90% of the particles by volume are within a range of about 10 μm to about 100 μm. The percentage of particles within any 10 μm band within the range does not exceed about 20% by volume, and the percentage of particles within any two adjacent 10 μm bands within the range does not deviate by more than about 8% by volume.