In April 2025, our ERA talent Dr. eng. Aleksandra Malachowska was introduced to cold gas spray (CGS) technology during a hands-on training session at the Impact Gun 5/8 M2-78 station.

The training was led by Alex Vidal, an experienced engineer from Ouest Coating, who provided both technical instruction and practical insights into the cold spray process. Under his supervision, Dr. Malachowska acquired essential skills in operating the Impact Gun equipment, managing the powder feed system, and optimizing spray parameters.

As part of the practical session, Dr. Malachowska took part in the cold spray deposition of a prototype roller, where the current electrolytic coating is being considered for replacement with a nickel-based cold-sprayed layer. This work supports ongoing efforts to enhance surface performance while reducing process costs and environmental impact.

In parallel, she contributed to the preparation of aluminum 6061-coated test samples as part of a certification process for Airbus. These samples were produced with stringent control over process parameters to ensure their suitability for aerospace applications.

During the same period, measurements of powder particle velocity using the OSEIR HiWatch CS2 high-speed imaging system were initiated. First data sets have already been collected for selected powders. The measurements are aimed at characterizing and optimizing the cold spray process and will be continued in the upcoming month to expand the dataset and refine process parameters.

We are looking forward to receiving further interesting news!