Nissan recently announced the groundbreaking application of cold spray technology for valve seat manufacturing in its new 1.5-liter turbocharged engine dedicated to e-POWER. This bold move sets a distinct benchmark in the automotive engine sector, marking a world first. The technology will initially be implemented in the Qashqai e-POWER produced at the Sunderland factory in the UK, with plans for gradual expansion to other markets.
In breaking traditional boundaries, Nissan has significantly innovated its valve seat design. While conventional engines often rely on sintered metal parts pressed into the cylinder head—an approach that, although common, limits the shape of the intake path and thus affects combustion efficiency—Nissan has turned the game around. By employing cold spray technology, Nissan can directly coat the surface of aluminum cylinder heads with a different metal powder, creating a high-strength valve seat layer. This innovation not only eliminates the assembly steps for components but also allows for greater flexibility in intake path design, promoting more intense turbulent flow and further stabilizing the combustion process. This design integrates Nissan's proprietary STARC 2 combustion concept, achieving an impressive thermal efficiency of 42%.
The importance of cold spray technology cannot be overlooked. This technique utilizes supersonic spraying to tightly bond metal powders without reaching the melting point, effectively avoiding the issues of brittle interfaces or gas holes that can occur in traditional welding processes. This method significantly enhances thermal conductivity and durability, which is particularly crucial in high-temperature and high-pressure valve areas. Moreover, Nissan employs its self-developed cobalt-free copper-based alloy, coupled with AI-driven quality inspection, showcasing its expertise in materials engineering and process control.
As for the further development of e-POWER technology, the core idea is to use the engine purely as a generator, providing power to drive the motor without the need for external charging, thus achieving an experience close to that of a fully electric vehicle. The new system incorporates a compact five-in-one electric module (which integrates the motor, generator, inverter, reducer, and accelerator), significantly enhancing fuel efficiency and cabin tranquility with its lightweight design. In addition to the Qashqai, Nissan also plans to expand this system to the Rogue in North America and the all-new Elgrand in Japan.
From different perspectives, Nissan's Cold Spray Bet can be considered a technological innovation. This process originates from the aerospace industry, effectively prolonging the lifespan of traditional internal combustion engines. In terms of market positioning, Nissan is not merely chasing extreme performance; instead, it aims to maintain the uniqueness of e-POWER in the hybrid market through high efficiency and reliability. Throughout the automotive industry, this also reflects the pragmatic approach of Japanese automakers towards Internal Combustion Engine + Electrification, not only paving the way for the transition to electric vehicles but also hoping to provide an alternative choice for drivers.
Amid the wave of electric vehicles, Nissan has chosen to double down on internal combustion engine technology, which might be seen as counterintuitive but actually reflects its strategy with walking on two feet. The cold spray valve seat not only showcases their technological prowess but also highlights the brand's stance: Nissan is not just about producing electric cars; they can also maximize the potential of engines. This kind of innovation embodies the relentless spirit of Japanese automakers. Regardless of how the future of internal combustion engines is predicted, they remain committed to perfecting this generation of technology, and that attitude is truly commendable.
