Hey George,
If I understand correctly this is about reconditioning a shaft part for a bearing fit. I think this is one of the most recurring applications for HVOF coatings. We do at least 2-3 parts/week for this purpose. We are based in antwerp, you can find more details on
https://www.amw.be. If you want to share more information (drawing, picture) or request a quotation you can send it to sales@amw.be.
But honestly I think any HVOF spray shop will be able to process your part.
The alternatives that I can think of are:
1. Flame spraying: this is a cheaper alternative and I wouldn't recommend it for parts turning at a high rpm/load due to the lower bond strength
2. Turning and choosing a lower size bearing but as you said this weakens the shaft
3. Laser cladding: this is a good technique that typically provides quality coatings but it induces more heat in your workpiece which might cause deformations (especially on parts that have been in service for a long time)
Good luck!
Best regards,
Jeroen