Depending on user requirements, propylene, propane, hydrogen or natural gas may be used as the fuel in gas-fueled HVOF thermal spray systems. As a result of the high kinetic energy transferred to the particles through both HVOF processes, the coating material generally does not need to be fully melted. Instead, the powder particles are in a molten state and flatten plastically as they impact the workpiece surface. The resulting coatings have very predictable chemistries that are homogeneous and have a fine granular structure.