The present study investigated the use of High Velocity Air-Fuel (HVAF) spraying to pro-duce oxide dispersion strengthened (ODS) bond coats for thermal barrier coatings. The development of nine coatings was achieved through the utilisation of two base powders (Amdry 386 and Metco 2253) and varying alumina contents ranging from 3 to 50 wt.%, employing hybrid and blended spraying techniques. The characterisation of the coatings was conducted through the use of scanning electron microscopy and image analysis techniques. Further-more, a series of tests were performed on the coatings to assess their response to isothermal oxidation and thermal cycling fatigue. The findings demonstrated that the utilisation of blended powders resulted in higher oxide content and more uniform distribution when compared with the use of hybrid spraying techniques. Alumina particles have been found to be preferentially embedded around splat boundaries, thereby enhancing both mechanical inter-locking and oxidation resistance. The performance of coatings based on the Amdry 386 pro-cess was found to exceed that of those based on the Metco 2253A process. The latter was found to be susceptible to Si-rich phase formation. Overall, coatings with higher alumina content demonstrated enhanced durability and a reduced propensity for the formation of deleterious mixed oxides within the thermally grown oxide layer. The findings confirm HVAF as a promising method for producing high-performance ODS bond coats. However, further research is required to optimise the spraying parameters and oxide incorporation.