NCAME partners with high-performance metal powder producer to evaluate cold spray for repair of critical components
Published: Jun 23, 2026 1:00 PM
By Joe McAdory
NCAME Research Engineer Mikyle Paul, right, and Hunter Ryan with the center's VRC Gen IV Cold Spray System.
Cold spray has become an increasingly attractive option for restoring and extending the life of critical components, yet industries still lack the mechanical‑performance data needed to confidently use the technology for repair applications.
A team of researchers at the National Center for Additive Manufacturing Excellence (NCAME), in partnership with 6K Additive, a U.S.-based manufacturer of premium metal powders and alloy additions, is investigating how various cold spray feedstock materials perform under demanding conditions.
“This project is about understanding how cold spray materials behave when they’re used for repair and sustainment operations in demanding environments,” said Mikyle Paul, NCAME research engineer who leads this project. “We’re evaluating the mechanical performance and strength of a range of feedstock materials so we can generate data that supports future repair strategies for critical components across defense and industrial sectors.”
Cold spray is an advanced manufacturing process that differs from traditional welding and thermal spray technologies. Rather than melting material, cold spray accelerates metal powder particles to extremely high velocities using compressed gas. When these particles impact surfaces, they plastically deform and bond to the substrate, creating a dense metallic deposit while minimizing the heat-related effects often associated with conventional repair methods. Because of its solid-state nature, cold spray has become an increasingly attractive technology for component repair, restoration and life extension in aerospace, defense, energy and other industries.
Research will be conducted using the center’s VRC Gen IV Cold Spray System. Results will help establish a deeper understanding of how cold spray materials can be effectively deployed for field repairs where reliability and structural integrity are critical.
“This project gives us an opportunity to generate the fundamental performance data needed to increase confidence in cold spray repair technologies,” said Scot Carpenter, NCAME laboratories manager. “By understanding the strengths and limitations of these materials, we can help accelerate their adoption for real-world repair applications where downtime, cost, and operational readiness are major considerations.”
Pete Bochinni, technology director at 6K Additive, emphasized the importance of industry and government collaboration in advancing repair technologies.
“Partnerships like this bring together material suppliers, researchers, and end users to solve practical challenges,” Bochinni said. “The knowledge generated through this work will help move advanced repair technologies closer to widespread implementation.”
NCAME Director Nima Shamsaei said the project aligns closely with the university's mission to advance manufacturing technologies while supporting national priorities.
“Research efforts such as this demonstrate Auburn Engineering's commitment to developing the next generation of advanced manufacturing solutions,” said Shamsaei, also the Philpott-WestPoint Stevens Distinguished Professor of Mechanical Engineering. “By combining world-class facilities, talented researchers, and strong industry partnerships, we are helping accelerate innovation and strengthen the future of manufacturing.
“This project further expands NCAME's growing portfolio of advanced manufacturing research and reinforces Auburn University's leadership in materials characterization, additive manufacturing and repair technologies. Through efforts like this, NCAME continues to support industry and government partners while providing valuable research opportunities that advance the state of manufacturing science and engineering.”
Media Contact: , jem0040@auburn.edu, 334.844.3447