A new preparation method was used to create a feedstock of pure Al powder to which a much finer TiC powder was attached. Cold spray (CS) coatings of pure Al, blended Al/TiC and satellited Al/TiC were applied to an Al substrates. A seven-fold increase in TiC area fraction was measured in the satellited coating compared to that in the blended coating.Coating thickness also increased as a result of increased ceramic deposition. Crosssectional analysis revealed that the cohesion achieved between Al and TiC, during satelliting process, survives the CS process, and is hence is demonstrated to be an effective method of producing ceramic-metal coatings.
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