Cold gas dynamic spray is a revolutionary technology that offers many advantages over traditional thermal spray techniques. It is a US patented technology based on a scientific discovery made in the former Soviet Union in the early 1980's. Cold gas dynamic spray technology is based on the discovery that particles moving at a supersonic speed adhere to a base surface upon collision with that surface. Since 1996, cold gas dynamic spray has been in full-scale production outside the USA. Now, it is finally commercially available in the USA through Rus Sonic Technology, Inc. We offer an extensive and versatile product line, which includes both "off-the-shelf" standard, spray machinery as well as customized machinery designed and built to specific customer specifications for custom applications.

OUR UNIQUE COLD GAS DYNAMIC TECHNOLOGY. We are the cold spray manufacturer in the world that can spray hard alloys with pure air as the gas carrier. Other manufacturers claim to spray hard alloys but they require helium or other exotic and expensive gas as their air carrier. Other manufacturers claim to have developed cold spray equipment but they can only spray soft metals. Still others claim to be able to sell their cold spray equipment in the commercial market, but we are the only manufacturer currently able to mass produce our equipment and provide portable equipment for the field. To our knowledge all other cold spray manufacturers must spray inside an enclosed chamber, making practical applications nearly impossible.

The application of cold gas dynamic spray technology as a metal spray coating method is straightforward: A powdered metal, metal/ceramic blend, or polymer is accelerated by compressed air through a supersonic nozzle and is sprayed on the surface to be coated. The hardness, porosity, and thickness of deposited coatings can be controlled by adjustments to the air pressure, pre-heater, and nozzle. Surface materials include metal and metal alloys, ceramic and glass, polymers, paper, and net screen and foil.

UNIQUE CHARICTERISTICS. Traditional thermal spray coating methods (plasma, electric arc, HVOF) require high temperature of material particles to adhere to a surface. Typically this temperature exceeds the material melting point thereby creating problems inherent in thermal spray. In cold gas dynamic spray - high temperatures are not required. This is what makes the technology unique. This technology utilizes the surface interaction of particles moving at supersonic velocities between mach 2-3 (required velocity is dependent upon application and gas carrier ). Since high temperatures are not required in cold gas dynamic spray, adhesion and porosity are superior to thermal spray. Traditional thermal methods -by definition- create undesirable chemistry changes and associated stresses along with defect causing oxidation. Cold gas dynamic spray utilizes supersonic velocity to spray material so fast into a surface that a strong bond is formed without the undesirable side effects inherent in conventional thermal methods. This technology has substantial benefits over traditional coating methods due to low temperatures, low porosity, and superior adhesion.

The attractiveness of the cold gas dynamic spray method is that the application equipment and deposited coatings have no limitations inherent in other thermal coating methods. The coating quality and adhesion are superior without the complexity of detonation or exotic gas deposition methods. Cold gas dynamic spray technology offers flexibility and economy for a wide variety of applications in a multitude of industries.







Uniform Microstructure / Low Porosity / High Adhesion

Ruthenium (Ru) Microstructure
of a border between surface & coating.

Microstructure of Cu+Al2O3 coating
on steel surface
Microstructure of 8812 WC-Co coating on steel surface.


  • Low Porosity/High Adhesion. Once the material collides with the substrate at supersonic velocity it disrupts the metal-oxide films on both the particle and substrate surfaces bonding their atomic structures together creating high-density bonds with porosity less than 0.5%.
  • Uniform Microstructure. The material is deposited on a surface at supersonic velocities and remains at or near room temperature until impact. The velocity upon impact is so great that a tight uniform bond is formed without the undesirable chemistry changes and stresses typically found in thermal spray. This process leaves the original structure of the substrate intact.
  • Negligible Temperature. Negligible heat is necessary to heat metal powders prior to depositing on surface. The coating is deposited under normal atmospheric pressure in any air temperature and air humidity.
  • Negligible to No Oxidation. Because there are no chemistry changes and stresses typically found in thermal spray, cold gas dynamic deposited materials exhibit negligible to no defect causing oxidation. This advantage applies specifically to corrosion prevention applications.
  • Safety. Because negligible heat is required, this technology can be safely applied in inherently dangerous industrial areas.
  • Environmentally Friendly. No high temperatures, dangerous gases or radiation, and no chemically aggressive wastes.
  • Chemically Dissimilar Materials. It is possible to bond chemically dissimilar materials with bonds that transition from one material to another. This advantage applies specifically to using cold gas dynamic spray as a low-temperature (safe environment) alternative to welding.
  • Versatile Product Offering. Standard or customized equipment. Metal spray ranging from hard to soft. Portable and compact equipment available for field service application and repair. Multi-spray nozzles available for wide-area spray and 360-degree rotating nozzle available for spraying inner/outer pipe applications. Powder reclamation and air filtration systems are available.








Technical Specifications

Based on Standard Equipment. Characteristics and Capabilities
Change Significantly Due to Custom Design & Application

  • Metals, metal blends, metal alloys, and ceramics: WC-Co, CrC-NiCr, Al, Cu, Al2O3, SiO2, SiC, Ni, Cr, Fe, B, C, Ti, Cr2O3, Zn, B2O, TiO2, WC, ZnB2, (TiB2+Ni+MoS2), (Ti+Ni), (TiC+Ni+MoS2), (TiB2+Ni), (C, Co, Fe, W), (C, Cr, Ni), (Al, Ni), (Al, Hf, Fe, Mg, Si, Ti, Y, Zr)
  • Polymers: epoxy resin, polyurethane, thermal plastic materials


  • Metals and metal alloys; ceramics and glass; polymers; paper; and net screen & foil.
  • Adhesion and cohesion : 4,350 to 14,500 psi
  • Hardness : 40 to 102 HRC
  • Roughness : Rz = 20 to 40
  • Porosity : less than 0.5%
  • Max thickness of a coating : 5 micron to unlimited
  • Air consumption range: 11 to 21 ft3/min
  • Air (gas) pressure : 58 to 150 psi
  • Air impact : 59 to 931 degree F
  • Velocity of the sprayed particles by air : 492 to 4,921 ft/sec
  • Width of spraying stripe for one pass : 0.4 to 2.0 in
  • Powder consumption :4.4 to 33 lbs/hr
  • Efficiency of spraying a coating : 2.2 to 18 lbs/hr
  • Spraying efficiency : 3.2 to 54 ft2 /hr

*Deposition efficiency is dependent on powder type and ranges from 50% to 85%. Powder consumption efficiency can also be increased through purchase and use of a reclamation system.

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