Nitinol shape memory alloy (SMA) Kinetic Metallization depositions have obtained thicknesses exceeding 0.025” with as-sprayed densities of >99%.  The following micrograph is of an etched KM Nitinol deposition after annealing.  There are no visible boundaries visible from the original powder size.  The visible grains are larger than the powder feedstock indicating diffusion and grain-growth beyond the particle boundaries.