Cold Spray Additive Manufacturing

Cold spray technology is emerging as one of the most important advanced manufacturing capabilities for the repair, sustainment, and production of high-performance metal components.

Unlike traditional welding or thermal spray processes, cold spray accelerates metal powders to supersonic velocities and bonds them to a surface without melting the material.

This solid-state process eliminates heat-affected zones, reduces distortion, and allows metals to retain their original mechanical properties.

These characteristics make cold spray particularly valuable for defence platforms, aerospace systems, and heavy industrial equipment.

Cold spray allows damaged components to be repaired or rebuilt directly on the asset without disassembly.

This capability has major advantages for industries where downtime is costly, including:

• Naval vessels and maritime infrastructure
• Aerospace systems
• Mining and heavy equipment
• Oil and gas infrastructure
• Rail transport systems

In defence applications, cold spray enables rapid restoration of critical components, extending the operational life of complex platforms.

Cold spray can also be used as a form of additive manufacturing, enabling the layer-by-layer production of metal components using materials such as aluminium, titanium, copper, and nickel alloys.

This capability supports the rapid production of high-performance parts while reducing waste and material consumption.

Cold spray coatings can apply multi-metal protective layers that significantly improve corrosion resistance in harsh marine environments.

These coatings can also reduce surface drag, improving performance and extending the service life of naval vessels and offshore infrastructure.

Cold spray technologies present a major opportunity for regional manufacturing centres such as Central Queensland.

Industries that could benefit include:

• Mining equipment rebuild and refurbishment
• Heavy machinery repair
• Marine and offshore infrastructure
• Rail component restoration
• Defence sustainment and logistics

Mobile cold spray systems could allow advanced repair capabilities to be deployed directly to remote industrial sites, significantly reducing downtime and logistics costs.

Through collaboration with industry partners across the AUKUS alliance, the Advanced Welding Alliance aims to support the adoption of these advanced deposition technologies within Australia’s manufacturing sector.