To enhance the wear resistance of cold-sprayed titanium coatings, a hybrid technique combining initial laser processing with subsequent micro-forging assisted cold spraying was employed to fabricate a highly relative density (99.35%) Ti6Al4V-TiNp composite coating. The regulation mechanisms of solid-solution and aging heat treatment on its microstructure and wear performance were systematically investigated. The robust metallurgical bonding between TiN particles and the titanium matrix is facilitated by the in-situ formation of the Ti 2 N phase under the optimized heat treatment regime (HT2: 850 °C solution treatment followed by 550 °C aging), and the cohesive strength among Ti6Al4V powder particles is also improved. Dispersed intragranular β-Ti nanocrystals and intergranular β laths are precipitated in the matrix, and the strengthening and toughening design of the matrix is achieved via the Orowan looping mechanism and the inherent plasticity of the β phase itself. Under the HT2 regime, the composite coating achieved the highest microhardness (reaching 558.03 HV) and optimal wear resistance. Its wear rate was as low as 0.46×10 -4 mm 3 /(N⋅m), representing reductions of 77.1% and 72.1% compared to the Ti6Al4V sheet and the as-sprayed coating, respectively. The wear mechanism transitioned from the mixed mode dominated by particle detachment in the as-sprayed state to mild abrasive wear characterized by the formation of a continuous protective transfer film. The improved wear performance under HT2 is associated with the combined effects of enhanced interfacial bonding, matrix strengthening, and increased coating hardness.
Liang et al. (2026) studied this question.