Abstract: A method of fusing a thermal spray coating to a base material employs infrared heating. The thermal spray coating is applied to the base material in a conventional manner. The infrared heater applies unidirectional heat in a first time-temperature relation to the coating during a fusing phase to melt individual coating platelets into a dense layer and to metallurgically bond the coating to the base material. In a base material that is heat treatable, the base material can be heat treated subsequent to the fusing phase. Initial heat treating of the base material occurs during the fusing phase. Continued heat treating of the base material is achieved after the thermal spray coating fusing phase by a second application of time-temperature from the infrared heater. A cold wall process can be used to aid in the quenching phase of the heat treating process.