Abstract: A metal or alloy powder is cold sprayed onto a turbine engine component to form a bond coat. The bond coat is shot peened with particles at a sufficient velocity to compact and smooth the bond coat surface. The smooth surface promotes the formation of a stable and adhered alumina TGO layer. According to another embodiment, the bond coat is instead cold sprayed with particles at a velocity that is sufficient for the particles to compact and smooth the bond coat, and that is insufficient for the particles to bond with the bond coat. For both embodiments, a heat treatment process under controlled atmosphere may be necessary to promote bonding between bond coat and substrate and as a pre-oxidation step to form the TGO layer.