Traditionally, power plants have used thermal spray methods such as HVOF and plasma spray, which melt the coating material before it is applied. These are effective but energy-intensive.
| Photo Credit:
Getty Images
The International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI) has developed a cheaper, greener way to apply protective coatings using the cold spray technique. Instead of relying on costly gases like nitrogen or helium, ARCI’s method works with ordinary air.
Cold spray creates ultra-durable coatings by blasting fine metal particles at supersonic speed, so they stick to a surface without melting. Traditionally, power plants have used thermal spray methods such as HVOF and plasma spray, which melt the coating material before it is applied. These are effective but energy-intensive. Cold spray is safer for the material, but its dependence on expensive gases has limited its use.
ARCI overcame this by designing patented, energy-efficient nozzles that make air-based cold spray viable. Their design keeps particles longer in the thermal jet, heating them just enough to bond well without extreme conditions. Using standard nickel-chromium powders, ARCI produced dense coatings that resisted 1,000 hours of heat cycling at 1,100 degrees C, thanks to a stable protective oxide layer.
The result is a cost-effective, sustainable solution for extending the life of components in power plants — combining smart engineering with material science.
Published on August 25, 2025
