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Elemental aluminum powders and elemental titanium powders were ball-milled to fabricate Ti/Al composite powders with different titanium to aluminum ratio using several kinds of organic solvents as a process controlling agent. The organic solvent was decomposed during milling and the carbon was incorporated in the composite powder. The carbon content of the composite powder depended on the kind of the organic solvent. The composite powders were low pressure plasma sprayed onto a steel substrate to produce coatings. The coatings deposited on a water cooled substrate were predominantly composed of a metastable Ti3Al phase that was supersaturated with carbon. Heat treatment of the coatings led to the decomposition of the Ti3Al phase to a TiAl phase and fine Ti2AlC. When the thermal spraying was carried out on a preheated substrate, the main constituent of the coatings was a stable TiAl phase and Ti2AlC was detected by X-ray diffraction. The as-sprayed coating possessed a high hardness. Fine Ti2AlC particles appeared after heat treatment of these coatings. The volume percentage of the Ti2AlC ranged from 4.9% to 15.3% depending on the coating composition.

Titanium Aluminides Based Composite Coatings with Fine Carbide DispersoidsProduced by Reactive Spraying of Ti/Al Powders Containing Carbon