Fusible coatings of Nickel-Chromium alloys with various amounts of Boron and Silicon commonly used for severe load applications. The coating is normally sprayed, then fused by heating to the point of liquation. The fusing process causes powder coalescence and increases density. At the same time, the high fusing temperatures creates a “brazed” bond which gives these coatings extremely high adhesive bond strengths. The improved bond strength is the result of the metallurgical bond as compared to the majority of thermal spray coatings which rely only on mechanical bonding mechanisms. The fusing operation is very sensitive, especially when a hand torch fuse is required. To circumvent these problems, a study was conducted to see if high density HVOF sprayed coatings might achieve fused quality by furnace heating to temperatures well below the liquation point. Various times and temperatures were surveyed. Bond strength tests of coatings sprayed to heavy thicknesses, hardness and impact tests, and metallography were used for evaluation. It was determined that heating as low as 1500° F for three hours could improve the properties of an as-sprayed HVOF coating to where it developed characteristics very similar to that of a fused coating.