Abstract:In this study, cold spray (CS) and low pressure plasma spray (LPPS) were chosen to fabricate the Ni-Ti composite coatings using a mechanically mixed powder of Ni/Ti at the atomic ratio of 1:1 aiming to avoid the oxidation. Upon utilization CS and LPPS techniques, spray processes played a significant role in the microstructures, phase compositions, mechanical property, and wear and corrosion performances of the two coatings. Results show that no oxidation was characterized in these two coatings. Nevertheless, two very different coating structures were found. CS coating showed a much lower porosity and a mechanical bonding of plastically deformed particles, and XRD denoted no NiTi intermetallic was formed during CS deposition. However, high temperature would lead to the significant differences in the LPPS coating, which exhibited a lamellar structure with the formation of Ni-rich and Ti-rich intermetallics around the interface. The LPPS coating presented the excellent performances due to the element diffusion during LPPS process. For example, it yielded a higher hardness value, which was nearly three times higher than that of CS coating. It was also given that a significant reduction of wear rate. In addition, a much higher corrosion potential and a much lower corrosion current also indicated a better corrosion resistance of LPPS coating.