Cold Spray Additive Manufacturing (CSAM)

About

Cold-sprayed additive manufacturing (aka CSAM or cold spraying) is a manufacturing process where powdered material (e.g., metals, ceramics) is deposited via a carrier gas at below-melting temperatures and supersonic speeds. The material particles in the powder undergo plastic deformation upon contact with a target surface, and the deposited particles are held together via mechanical bonds to form a uniform layer.

A very new process, cold spraying was conceived in the 1990s. Since then, research has been attempted to characterize the cold-spray process and cold-sprayed materials. The FATSLab team focuses on creating and testing new composite materials via cold spraying as well as characterizing the CSAM process. Some of our research is listed below.

See the video beside for a look into the Cold Spray Hub, a database of cold spray-related papers developed via a collaborative effort between the FATSLab team and the University of Ottawa's Cold Spray Lab and Modern Management of Data and Analytics Lab (M2oDA).

Cold Spray Hub

View "Cold Spray Hub" on YouTube

New Materials/Structures and Applications

FATSLab research explores new combinations of substrate and cold-sprayed material to generate new structures and materials. Applications of cold-sprayed combinations are also explored. 

References

Journal Publications

Oheil M., Saha D., Jahed H., Gerlich A., "Dissimilar Resistance Spot Weld of Ni-Coated Aluminum to Ni-Coated Magnesium Using Cold Spray Coating Technology," Metals, 15 (2025) 940.

Marzbanrad B., Marzbanrad E., Jahed H., "A Novel AA6061 Powder Reinforced with Al2O3 Nanoparticles for Cold Spray Deposition," Journal of Thermal Spray Technology, 35 (2026) 325-337.

Eftekhari N., Jahed H., "Comparative Analysis of Microstructural and Mechanical Attributes in Low-Pressure Cold-Spray Coatings: Impact of Varied Cu Feedstock Powders," Journal of Thermal Spray Technology, 33 (2024) 629-651.

Conference Proceedings

Eftekhari N., Jahed H., "An innovative approach to enhancing strength and ductility in cold spray 3D printing through engineered heterogeneous laminate microstructures," Proceedings of the Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Vol. 1, No. 1 (2025).

Oheil M., Jahed H., Gerlich A., "Fatigue of Cold Spray-Assisted Resistance Spot Welding of Aluminum to Magnesium," Proceedings of the Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Vol. 1, No. 1 (2025).

Woo A., Marzbanrad B., Jahed H., "Process parameter optimization and characterization of cold spray pure and blended AA6061 powder depositions," Proceedings of the Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Vol. 1, No. 1 (2025).

Marzbanrad B., Marzbanrad E., Jahed H., "Potential of cold spray technology for 3D printing of dense TiO2 green parts," Proceedings of the Holistic Innovation in Additive Manufacturing (HI-AM) Conference, Vol. 1, No. 1 (2025).

Simulations and Modelling

Characterizing the process and effects of cold spraying using numerical and statistical models, e.g., residual stress, bonding.

References

Journal Publications

Hirmand M.R., Tang J., Jahed H., "A Particle-Based Numerical Model for Impact-Induced Bonding in Cold Spray," Journal of Thermal Spray Technology, 33 (2024) 1886-1913.

Marzbanrad B., Toyserkani E., Jahed H., "Customization of residual stress induced in cold spray printing," Journal of Materials Processing Tech., 289 (2021) 116928.

Marzbanrad B., Jahed H., Toyserkani E., "On the evolution of substrate's residual stress during cold spray process: A parametric study," Materials & Design, 138 (2018) 90-102.