The use of the thermal sprayed coatings for the repair of mismachined or worn components is well known. The materials used for these coatings can either be metallurgically similar to the substrate material or of a material that will provide additional desirable surface characteristics, such as wear resistance. The coatings can be applied quite thick and are easily machined to dimension and the required surface finish.

The use of thermal spray coatings for dimensional restoration is often faster and more reliable than conventional welding. Thermal spray coatings are quickly applied and do not metallurgically alter the substrate material.