FUTURE MANUFACTURING

www.csiro.au

Cold Spray Technology

Rapid low-cost, low-waste manufacturing

Cold Spray Technology is an innovative industrial coating technology system which

replaces conventional electroplating. It offers a more efficient, cost effective and
environmentally friendly process which can be applied to industries from biomedical
through to aerospace.
The technology

Form a metallurgical bond

CSIRO has established a well equipped

Cold Spray laboratory to provide
Australian industry the opportunity to
access this method of applying coatings.
It also enables the manufacture of
objects in-house.

Do not undergo undesirable chemical

Conventional thermal spray processes

preheat the material to be sprayed. The
spray droplets hit the object while semimolten and as they cool, they contract
slightly, creating stresses at the interface
and within the coating. These stresses
can cause defects later. By contrast, Cold
Spray materials generally:

Remain at or near room temperature

until impact

Come into contact with the substrate

at speeds of between 500 and 1500
metres per second

changes and stresses.

Researchers believe the key to the

process is the high velocity impact,
which disrupts thin oxide films on the
surface of the particles and substrate.
This means that the momentarily high
pressures between the interfaces force
their atomic structures into contact.
Using this method, it is possible to build
3D objects by spraying powder onto a
net or web substrate.
The main advantage of Cold Spray is
that the process is more efficient, cost
effective and environmentally friendly.
Others include:

Retaining initial chemical composition

of particles

The laboratory is able to manufacture objects in-house.

Depositing oxygen-sensitive materials

without vacuum

Low oxide content

High thermal and electrical
conductivity

High hardness and cold work

microstructure

Creating corrosion-resistant coatings

Depositing plastic coatings without
the need for volatile solvents

Intermetallic coatings or repair

(phase and compositional stability)

Depositing metal on ceramic or metal

on glass

Ability to perform rapid prototyping.

The Cold Spray technology produces
coatings with a gas-jet temperature that
is lower than thermal spray processes
such as powder flame, wire arc, plasma
arc and high-velocity oxygen fuel
spraying.

Its low temperature nature is likely to be

useful for the 70 per cent of materials
which are suitable as spray coating but
cannot withstand the high temperatures
required by thermal technology.

Market and application

Any industry that uses thermal spray
systems is likely to be able to use Cold
Spray technology. Examples include:

Biomedical prostheses with

improved wear

Aerospace fatigue-resistant coatings

Chemical improved corrosion
resistance

Mineral processing improved

corrosion and erosion resistance

Die casting extending die life

Electronics creating a heat sink or
superconductive surfaces

Printing copper coating on rollers

Oil and gas improved corrosion
resistance

Glass platinum coating.

Depositing oxygen-sensitive materials

without vacuum.

Further advantages include being

able to reduce or eliminate the use of
chemicals in conventional electroplating.
It also minimises electricity and water
use and does away with recycling
problems created by the use of heavy
metals, copper sulphates and acids. Cold
Spray technology could permit direct
fabrication of near-net shapes of metals,
composite and polymeric materials,
at room temperature with little or no
melting.

conductive patterns in solar cells. Wind

power generation may be able to make
use of Cold Spray to enhance surface
performance in components made of
advanced polymer matrix composites.

With environmental and health and

safety regulations becoming more
stringent, Cold Spray presents a greener
alternative.
An example of Cold Spray in use is
a development project on a direct
manufacturing technology for producing
seamless titanium pipe.
As the technology evolves it is likely to
expand to less traditional applications,
such as photovoltaic and wind power
generation. In photovoltaic applications,
it could be used to fabricate complex

Cold Spray technologys strengths lie in

the capability for:

Direct fabrication of low-defect parts

About us

Repairing defective areas without

Joining chemically dissimilar materials

CSIRO is Australias national science agency that has within it a number

of flagships that translate research into real world impacts. The Future
Manufacturing Flagship (FMF) works primarily with industry to provide
manufacturing research and commercialisation services.

A low-temperature alternative to

FMF operates within three focus areas based around sustainable and high
performance materials, advanced processing and the development of
disruptive or transformational manufacturing technologies.

changing the structure

with bonds that gradually transition

from one material to the other
welding

Building a composite component

using different materials in different

locations

Each of these focus areas has within it cutting edge expertise that can be
deployed for the benefit of our clients. Flexible engagement models in coinvestment and contract research or the licensing of intellectual property
are available to enable the development of strong and durable partnerships.

Retaining the properties of the

original particles

CONTACT US

YOUR CSIRO

FOR FURTHER INFORMATION

t 1300 363 400

+61 3 9545 2176
e enquiries@csiro.au
w www.csiro.au

Australia is founding its future on

science and innovation. Itsnational
science agency, CSIRO, is apowerhouse
of ideas, technologies and skills for
building prosperity, growth, health and
sustainability. It serves governments,
industries, business and communities
across thenation.

Future Manufacturing Flagship

Dr Mahnaz Jahedi
Research Leader
Cold Spray Technology
t +61 3 9545 2064
e mahnaz.jahedi@csiro.au
w www.csiro.au/Future-Manufacturing
Mr Mark Burgess
Director, Business Development and
Commercialisation
t +61 3 9545 2114
e mark.burgess@csiro.au
w www.csiro.au/Future-Manufacturing