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Rapid development of cold spray technology has made it a viable option to remanufacture and repair damaged engineering components made of Ti-6Al-4V (Ti64). This solid-state deposition process contributes to the distinctive microstructure of Ti64 coatings. In this study, the microstructural evolution of Ti64 from feedstock powder to coating as a result of high strain rate deformation is evaluated. TEM lamellae were extracted from the particle-substrate and particle-particle interfaces of a cold sprayed coating by focused ion beam milling and a comprehensive microstructural analysis was carried out. The feedstock powder is predominantly composed of martensitic lathes. The microstructure of the coating at the particle-substrate interface is noticeably different from the microstructure of the feedstock powder. Narrow regions consisting of nanometre-sized grains are observed in both the particle and substrate in the …