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In this study, for the first time, titanium powder recycled from machining swarf was used for cladding a novel Ti-Fe coating on a titanium substrate. Post deposition microstructures revealed a dendritic structure throughout the composite coating followed by a fine martensitic α′-Ti phase in the heat affected zone. Additionally, iron in the form of Fe 2 O 3 and Fe 2 C along with TiC and TiO 2 phases were also found which significantly contributed to the very high hardness (620-815 HV) of the coating. This hard composite coating can effectively improve the wear resistance of the titanium alloy, thereby finding applications in the aerospace and defence industries.

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