the nozzle orifice as depicted in fig1 the nozzle 4 of fig1 is shown in greater detail in fig2 electrode 6 is positioned at the mouth 18 of orifice 20 of nozzle 4 the mouth 18 of nozzle 4 is flared so that the volume of the nozzle at the mouth increases as shown the nozzle is chamfered or beveled however the flaring can be achieved by any other geometric configuration such as a mouth having a concave or parabolic opening a deflector 22 is positioned in mouth 18 surrounding electrode 6 powder particles traveling through orifice 20 of nozzle 4 are deflected outwardly by deflector 22 as they reach the nozzle a shown in fig2 and also are charged by electrode 6 as they pass through mouth 18 electrode 6 as shown in fig2 is connected to a power source via resistive wire 24 positioned in wall 26 as previously noted this is but one configuration for the nozzle of a powder spray gun any other configuration that imparts a charge to powder particles exiting the nozzle may also be used fig3 schematically depicts an exemplary embodiment of the equipment used for the process of the invention in greater detail in a spray room operation a gas turbine engine substrate is depicted mounted in a chamber 30 and connected to ground at 14 nozzle 4 of power spray gun 2.