Recently, vacuum plasma spray forming (VPSF) has been identified as a process capable of manufacturing near-net-shape components for advanced technology applications such as aerospace, defense, and chemical process industries. By optimizing the deposit structure via intelligent control of process parameters and utilizing post-deposition heat treatments, deposit structures with properties better than conventionally cast materials and, in some cases, equivalent to wrought materials can be produced. In this study, VPSF process has been employed to form near-net-shape structures of one of the most important and widely used titanium alloys, Ti-6Al-4V. Since the quality requirements for sprayed structural materials are different than those for coatings, characterization of the standard coating parameters does not fully address the microstructure requirements that must be met to assure optimal properties. The initial powder, as-sprayed structure and splat formation of the alloy during thermal spray process were investigated comprehensively in this study. Three heat treatment cycles were developed to achieve desired physical and mechanical properties of the VPS deposited material.
