This study investigates how torch standoff distance influences the microstructure, surface topography, and progressive-load scratch response of air plasma-sprayed 8YSZ and rare-earth co-doped GdYbYSZ thermal barrier coatings on an St-52 grade carbon steel substrate. Three nozzle-to-substrate spraying distances were examined: 80, 100, and 120 mm. X-ray diffraction revealed that the 8YSZ coatings possessed a predominantly tetragonal (t′) structure, with minor monoclinic fractions detected in the coatings obtained with the 80 mm and 100 mm distance parameters. The GdYbYSZ coatings, in contrast, exhibited a single-phase cubic defect-fluorite structure; their diffraction peaks appeared at lower 2θ angles relative to undoped cubic ZrO2, consistent with lattice expansion caused by the substitution of Zr4+ by the larger Gd3+ and Yb3+ cations. Surface topography was quantified by non-contact laser profilometry, providing areal (Sa) and profile (Ra) roughness parameters for the as-sprayed condition as well as three-dimensional scratch-damage morphology after testing. Progressive-load scratch tests were performed using a Rockwell diamond indenter over a 2 mm track with the normal load ramped from 0.03 N to 30 N. Penetration depth, residual depth, tangential force, and acoustic emission were recorded continuously to identify critical damage transitions. Across all spraying distances, 8YSZ exhibited systematically shallower scratch grooves than GdYbYSZ; end-of-track maximum groove depths remained below 37 µm for 8YSZ, whereas GdYbYSZ reached up to 72 µm under identical loading conditions. The novelty of this study lies in combining torch standoff distance as a processing variable with multi-channel progressive-load scratch diagnostics, including in situ acoustic emission, depth profiling, and friction monitoring, to comparatively assess the scratch wear performance of 8YSZ and rare-earth co-doped zirconia TBCs for the first time.