A method of forming a gun barrel includes providing a gun barrel with a desired wall thickness, and cold gas-dynamic spraying the gun barrel with a titanium powder to form an outer layer. The method may further include contouring the outer layer, applying a ceramic top coating to the contoured outer layer of the gun barrel, and sealing the gun barrel with a liquid metal sealer. The method may further include spraying the gun barrel with a bonding coating to form a bonding layer before cold gas-dynamic spraying the gun barrel.