A method is provided for repairing a surface portion of an article including a metallic environmental resistant coating on a substrate. The coating includes a coating outer portion bonded with the substrate through a diffusion zone that includes at least one feature, for example Al and/or an intermetallic phase, in an amount detrimental to application of a metallic replacement coating and/or repair of the article. The method comprises removing the coating outer portion to expose a surface of the diffusion zone. The substrate and the diffusion zone are heated at a temperature and for a time sufficient to diffuse and/or dissolve at least a portion of the at least one feature in the exposed surface and in a portion of the diffusion zone beneath the exposed surface to a level below the detrimental amount. This provides a replacement surface portion integral with diffusion zone. Then a metallic replacement coating outer portion is applied to the replacement surface portion. Provided is a coated article comprising a substrate and a metallic environmental resistant coating bonded with the substrate. The coating comprises an inner modified portion of the substrate integral with the substrate, an outer diffusion zone integral with the inner portion, and a metallic environmental resistant coating outer portion integral with the outer diffusion zone. In some forms, the coated article includes a thermal barrier coating over the metallic coating outer portion.