disclosed is a system and a method for applying both a kinetic spray applied coating layer and a thermal spray applied layer onto a substrate using a single application nozzle . the system includes a higher heat capacity gas heater to permit oscillation between a kinetic spray mode wherein the particles being applied are not thermally softened and a thermal spray mode wherein the particles being applied are thermally softened prior to application . the system increases the versatility of the spray nozzle and addresses several problems inherent in kinetic spray applied coatings .