An advantage of Air Plasma Sprayed (APS) Thermal Spray Coatings (TSCs) is that a used expensive component (e.g. a Titanium ball valve), can be: remachined, and recoated for approx. 1/3 of the cost of a new replacement. Occasionally machining renders the component undersize. Rather than scrapping the component, a single/multi pass GTAW overlay can be applied to re-establish required dimensions. The preconceived hypothesis is that residual Heat Affected Zone (HAZ) solidification stresses will result in a "measurable" decrease in adhesion strength of the APS Ceramic coating. This study was performed to determine the influence of a matching/overmatching composition GTAW weld performed on a linch diameter, 0.5inch length ASTM C633 "button". After welding, the C633 "buttons" are remachined parallel. A NiCrMo metal bond coat was HVOF applied, then 1 of 3 Ceramic coatings was applied (Cr2O3, 75%Cr2O3-25%Al2O3, and TiO2). Materials evaluated were: Alloy 20 Cb3, Titanium Grade 12, and S32205 Duplex SS. The following were evaluated for adhesion strength (ASTM C633): as machined (new) for reference, single pass GTAW weld, multi pass (3 passes) GTAW weld, and multi pass 100% coverage GTAW weld. All of the above samples were duplicated and thermally cycled (11 times) from ambient to 400°F/204°C, simulating service Coefficient of Thermal Expansion (CTE) stresses.