High pressure die casting (HPDC) is a well established manufactory process which allows, specially the automotive sector, to make high precision components in fast paced rates. Furthermore, the increasing need for lighter components stimulate the use of low density alloys, making the HPDC suitable for this emerging demand. Nevertheless, every manufacturing process has spaces for improvement. Regarding to HPDC many wear mechanisms cause it to fail or not be as well rounded over the time. Corrosion induced by molten metal is one of many failure modes for dies. Corrosion not only changes the geometry but also modifies the surface roughness, which may lead to die soldering. All combined wear not only changes the dimensional precision of the manufactured parts but also the surface quality, requiring rework. The maintenance is quite often expensive and its price imbedded to final product price. Many techniques are applied to decrease wear and even recovery the surface by additive methods. However, there is a lack of study on additive techniques and how farther the operation will be extended. The study of recovering HPDC machines components via thermal sprays still lacking on the literature. By thermal spraying mechanical components, it is possible not only to improve the surface properties but also recovery the geometry changes caused by aluminum attack. The main idea is to verify the possible use of thermal spray coating on surfaces exposed to wear on HPDC processes and how the aluminum interaction changes material properties and geometry.