Nissan Introduces Cold Spray Tech for Epower Engine Efficiency

In a significant advancement for automotive engineering, Nissan Motor Corporation has unveiled a groundbreaking innovation in engine technology. The company's new 1.5-liter turbocharged engine (codenamed ZR15DDTe) features the world's first application of cold-spray valve seat technology, marking a major leap forward in powertrain efficiency and manufacturing processes.

At the heart of Nissan's technological achievement lies its proprietary ST (Strong Tumble & Appropriately stretched Robust ignition Channel) combustion concept. This innovative approach achieves an impressive 42% thermal efficiency through precise control of in-cylinder airflow patterns.

Traditional engine designs typically rely on high turbulence for fuel-air mixing. Nissan's ST concept takes a different approach by minimizing turbulence in the intake port while creating powerful tumble flow within the combustion chamber. This tumble motion promotes more uniform mixture distribution and faster flame propagation, resulting in more complete combustion.

The implementation of this concept faced a significant engineering challenge: conventional pressed-in sintered valve seats limited designers' ability to create the complex port geometries needed for optimal tumble flow. Nissan's solution came in the form of cold-spray valve seat technology, which allows valve seats to be formed directly onto the aluminum cylinder head surface without separate components.

Nissan's cold-spray valve seat technology represents a fundamental shift from traditional manufacturing methods. The process involves accelerating specially developed metal powder particles to supersonic speeds using compressed gas. When these particles impact the cylinder head surface, their kinetic energy causes them to bond firmly in a solid state, creating a durable coating.

This approach offers several advantages over conventional thermal spray techniques:

• Eliminates heat-related material degradation
• Produces denser coatings with fewer pores
• Maintains base material properties
• Reduces thermal stress on components

For this application, Nissan developed a unique cobalt-free, copper-based alloy that combines excellent thermal conductivity with environmental sustainability. The company also implemented artificial intelligence-driven quality control systems to ensure process consistency.

The new engine technology debuts in Nissan's third-generation e-POWER system, first appearing in the recently launched Qashqai compact crossover. This system represents Nissan's unique approach to electrification, combining a gasoline engine that functions solely as a generator with electric motor propulsion.

Key advantages of the e-POWER system include:

• Pure electric driving experience with instant torque delivery
• No need for external charging infrastructure
• Superior fuel efficiency compared to conventional hybrids
• Reduced noise and vibration

The latest iteration features a new 5-in-1 modular electric drive unit that combines motor, generator, inverter, reducer, and increaser into a single compact package. This integration improves efficiency, reduces weight, and enhances packaging flexibility.

Nissan plans to expand e-POWER technology across its global lineup. The next implementation will appear in the North American market's Rogue SUV, followed by a new Elgrand minivan in Japan scheduled for 2026.

This strategic rollout positions e-POWER as a compelling alternative for consumers seeking electric vehicle characteristics without range anxiety or charging infrastructure dependence. The technology bridges the gap between conventional hybrids and full battery-electric vehicles, offering a practical transition solution in markets with varying electrification readiness.

Nissan's innovations in combustion engine technology and electrified powertrains demonstrate the company's commitment to sustainable mobility solutions. The cold-spray valve seat breakthrough not only improves current engine efficiency but also establishes new manufacturing paradigms that could influence future automotive production methods.