Because of their low density, high specific strength, and high stiffness, titanium alloys are one of the prime candidates for structural application often requiring specific tribological properties. However, their relatively high friction coefficients and low wear resistance are limiting their application over a wider range of temperature. Various coating technologies are currently available to enhance the surface by improving wear and friction characteristics. While the most widely used methods (High-Velocity Oxy-Flame (HVOF), Detonation-Gun (D-Gun), Electron-Beam Physical Vapor Deposition (EB-PVD), etc.) can improve wear performance and decrease corrosion damage, the required higher temperatures usually preclude the integration of thermally vulnerable lubricants. In this research, a low temperature, High-Velocity-Particle Consolidation process (HVPC) was investigated for coating Ti-6Al-4V due to its various advantages over conventional thermal spray processes. The optimum feedstock (nickel + solid-lube) for self-lubricating coating has been developed and compared with respect to different particle sizes and particulate composites. The coating characteristics and its microstructural homogeneity were assessed at various operating parameters and feedstock compositions.

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