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Nissan introduces world’s first valve seat using cold spray technology

​Nissan has adopted valve seats manufactured using cold spray technology – marking a world-first application in automotive engines.

Cold spray technology is now being applied by Nissan to its new 1.5-litre turbocharged engine, which is exclusively designed for power generation within the third-generation e-POWER hybrid powertrain.

The first vehicle globally to feature this new e-POWER system is the Qashqai compact crossover, which began production at Nissan’s state-of-the-art factory in Sunderland in July.

The new 1.5-litre turbocharged engine employs Nissan’s proprietary STARC 2 concept, which elevates thermal efficiency to 42% by stabilising in-cylinder combustion.

A key element of the STARC concept is minimising airflow turbulence from the intake port into the combustion chamber, thereby generating a strong tumble flow.

In conventional engines, the design of the intake port is constrained by the necessity for press-fitted, sintered valve seats 3, which limit the ability to optimise port shape for ideal tumble flow. Nissan engineers addressed this challenge by developing a novel valve seat using cold spray technology.

This process allows a coating to be directly formed onto the cylinder head surface, eliminating the need for a separate valve seat component and enabling the creation of an optimised intake port geometry. Furthermore, compared to similar methods, its higher thermal conductivity enables improved cooling performance around the valves.

The new valve seat is produced by spraying dissimilar metal powders at supersonic speed onto the aluminum alloy cylinder head surface, forming a robust and durable coating that adheres strongly without melting the base material.

Cold spray technology operates below the melting points of the materials involved, enabling the bonding of dissimilar metals without melting. This process prevents the formation of excessive intermetallic compounds and micro-voids (porosity) that are common in traditional fusion welding methods.

Crucial qualities

As a result, cold spray coatings exhibit superior adhesion, durability and reliability – crucial qualities for engine valve seats.

This application represents a world-first in automotive engines and leverages Nissan’s extensive expertise in powertrain design, materials engineering and manufacturing. The process incorporates a specially developed cobalt-free, copper-based alloy with excellent thermal conductivity, in-house nozzles inspired by polishing techniques used in forged mould production, and AI-driven quality assurance systems.

These innovations reflect years of accumulated know-how, enabling the successful implementation of cold spray technology in engine valve seats.

Following the Qashqai, Nissan plans to introduce new e-POWER in the U.S. and Canada on the next generation Rogue, as well as the Japan with the all-new Elgrand large minivan in FY26.