An alternative joining and repair process is being developed for titanium aircraft structures such as on the F-22 fighter. In this study, CP Ti and Ti-6-4 powder metal structural deposits were applied to Ti-6-4 substrates using an innovative low-temperature spray process called Kinetic Metallization. Physical and mechanical properties of the sprayed CP Ti and Ti-6-4 deposits as well as the joint strength between the sprayed titanium deposits and Ti-6-4 substrate were evaluated. Also, oxygen contents were measured in the starting powders as well as the sprayed deposits. Properties were characterized in the as-deposited condition and following post-deposition heat treatment. Kinetic Metallization (KM) is a solid-state powder metal spray process developed by Innovative Technologies, Inc. (dba Inovati) of Santa Barbara, CA. In the KM process, micron-size powder particles are entrained in an inert carrier gas and are accelerated to high velocities (500-1000 m/sec) through a specially designed, friction compensated spray nozzle. The powder particles have sufficient kinetic energy to plastically deform and metallurgically bond during impact on a metallic, ceramic, plastic or glass substrate. Because the KM process is done at low temperatures and in an inert environment it is especially well suited to materials that are sensitive to impurity pickup like titanium. Also, because there is no bulk melting the original microstructure and properties of the powder particles are retained.