In this study, pure titanium powder with an average size of 20 μm was treated by electroless nickel plating to obtain titanium–nickel composite/duplex powder. Two plating procedures were applied; continuous short period (CSP) and discontinuous long period (DLP) processes. The plated titanium powder particles as well as unplated ones were characterised by energy dispersive spectrometry (EDS), scanning electron microscopy (SEM), particle size analysis and X-ray mapping analysis methods. The nickel plated titanium powder was sprayed on the steel substrate by atmospheric plasma spray technique. Furthermore, the mixed titanium–nickel powder was also sprayed. The morphology of sprayed powders was compared with each other. It was found that nickel forms fine dispersed nodules on the surface of titanium powder particles in the CSP process, whereas it appeared as homogeneous layers on the surface of all the particles in the DLP process. Also, it was found that the mass deposited on the powder increased with the plating period. The sprayed nickel plated powder showed better microstructure than the sprayed nickel mixed one.
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