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Related Experiment Video

Updated: Jan 11, 2026

Processing of Bulk Nanocrystalline Metals at the US Army Research Laboratory

Processing of Bulk Nanocrystalline Metals at the US Army Research Laboratory

Published on: March 7, 2018

Cold-Sprayed Ni and NdFeB-Al Powders Recovery and Reuse.

Jean-Michel Lamarre¹, Alexandre Nascimento², Cindy Charbonneau¹

¹National Research Council Canada, 75 Boul. de Mortagne, Boucherville, QC J4B 6Y4, Canada.

Materials (Basel, Switzerland)

|November 13, 2025

Summary

Recovering and reusing cold spray powders, like nickel and NdFeB-Al, improves process economics. Even after multiple cycles, recovered powders maintain their performance for additive manufacturing applications.

Keywords:

NdFeB Nickel cold spray magnets powder recovery sustainability

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Last Updated: Jan 11, 2026

Processing of Bulk Nanocrystalline Metals at the US Army Research Laboratory

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Published on: March 7, 2018

Chemical Precipitation Method for the Synthesis of Nb2O5 Modified Bulk Nickel Catalysts with High Specific Surface Area

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Published on: February 19, 2018

Preparation and Reactivity of Gasless Nanostructured Energetic Materials

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Published on: April 2, 2015

Area of Science:

Materials Science
Additive Manufacturing
Powder Metallurgy

Background:

Cold spray additive manufacturing faces challenges with low deposition efficiency for certain materials, leading to feedstock waste.
Economically viable mass production and use of expensive materials necessitate solutions to powder waste.

Purpose of the Study:

To investigate the feasibility and impact of powder recovery and reuse in cold spray processes.
To evaluate the effect of recovery on powder characteristics and coating performance for Ni and NdFeB-Al powders.

Main Methods:

Development and testing of a prototype powder recovery system.
Characterization of recovered powder morphology and size distribution after multiple spray runs.
Evaluation of magnetic properties of powders and coatings using hysteresis measurements.

Main Results:

The prototype recovery system achieved up to 75% recovery efficiency.
Recovered Ni and NdFeB-Al powders, even after four spray runs, remained suitable for re-deposition.
NdFeB-Al powder retained 97% of its initial magnetic performance under industrial conditions.

Conclusions:

Powder recovery and reuse is a viable strategy to improve the economics of cold spray additive manufacturing.
Despite minor alterations in particle size and magnetic properties, recovered powders maintain performance for repair and permanent magnet fabrication.