In this study, titanium and aluminum powders mixed in different ratios were deposited on stainless steel substrates by warm spraying. Microstructure and composition of as-sprayed and heat-treated samples were characterized and the effect of adding a third element was assessed. It was found that Al content has a major influence on the thickness and porosity of heat-treated Ti-Al coatings and that adding silicon to the powder mixtures reduces the melting point of Al, causing a loss of Al-Si particles during spraying.

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