Compared to thermal spraying, the cold spray (CS) process features virtually oxide-free coatings without thermal defects and residual stress, and it is suitable for processing Ti and its alloys. This review focuses on microstructure control and current properties of CSed Ti and its alloys coating to elucidate and expand their applications. A critical overview of the main processing parameters governing the microstructure of the coating has been presented and discussed, combined with some useful results from the studies reported by various research groups. The porosity and mechanical properties of CSed Ti and its alloy coatings have been summarised. A synopsis of the measurement techniques of each property has also been presented herein.
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