The HVOF process with reduced heat effect on the substrate and therefore minimal degradation of fatigue properties is now finding wide application in fatigue critical applications. The critical parameters for process control are residual stress in the deposit and maximum substrate temperature. Quality control tools for these parameters are deflection of Almen Strips (similar to shot peening) for simulating residual stress and the use of infared pyrometry for temperature measurement. Both of these methods are technically sensitive particularly in spraying of coupons to evaluate the effect of coating on material properties. Lessons learned will be presented and recommendations made for applications of these tools in controlling the HVOF process.