By means of homemade ultrasonic arc spraying equipment patented, under the condition of the optimum arc spraying parameters, TiAl alloy coatings were manufactured on the aluminum alloy (LY12) matrix surface. The ultrasonic arc spraying forming process and microstructure of TiAl compounds alloy coatings were investigated by the color metallurgical microscopy, SEM, XRD, EPMA and chemical composition quantitative analysis (ICP). The results showed that TiAl compounds composite coatings can be synthesized by ultrasonic arc spraying system, the coatings possess typical lamella character, consist of TiN (or TiO), TiAl, Ti0.7.1.1 Al(N,O), Ti2.4Al(N,O), Ti2.4Al and aluminum alloy solid solution.

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