Nissan has achieved a major technological milestone by introducing the world’s first automotive engine valve seats manufactured using cold spray technology for its all-new 1.5-liter turbocharged engine, exclusively designed for the next-generation e-POWER system. This breakthrough, pioneered at Nissan’s Yokohama facilities, debuts on the latest Nissan Qashqai, now rolling out of the Sunderland plant in the UK.
The Engine
Codenamed ZR15DDTe, the new 1.5-liter turbo engine employs Nissan’s patented STARC (Strong Tumble & Appropriately stretched Robust ignition Channel) combustion concept, pushing thermal efficiency to an exceptional 42%. This is achieved by minimizing intake airflow turbulence and optimizing fuel-air mixing at injection, translating to cleaner, more efficient combustion. Traditionally, the design of intake ports has been limited by conventional, press-fitted sintered valve seats. Nissan engineers overcame this by developing a novel cold spray method, applying metallic powders at supersonic speed onto the aluminum cylinder head, forming a robust, high-conductivity layer without melting the underlying substrate.
Advantages
Unlike fusion-based welding or sintering, cold spray operates below the melting point of the involved materials, preserving microstructure and avoiding unwanted intermetallic compounds or porosity often affecting conventional processes. The result: valve seats with superior adhesion, durability, and reliability—qualities essential for the high-performance demands of modern engines. The new cold-sprayed seats leverage a specially developed, cobalt-free copper alloy for outstanding heat conductivity, enabling better cooling around the valves and further optimizing engine performance. This process also employs internal nozzles inspired by forged mold polishing and AI-driven quality assurance systems.
e-POWER Powertrain
e-POWER distinguishes itself by offering full-electric drive—the wheels are powered solely by the electric motor, while the gasoline engine serves exclusively as a generator for the battery and inverter system, never transmitting power directly to the wheels. This results in a driving experience that combines the smooth, silent acceleration of an EV with the convenience of gasoline refueling, obviating the need for external charging. Since its 2016 introduction, Nissan continues to refine and expand e-POWER across global markets, including an upcoming introduction to the new-generation Rogue (US and Canada) and the next Elgrand minivan (Japan) in 2026.
A key element in the latest e-POWER evolution is the new 5-in-1 modular power unit, which integrates the electric motor, generator, inverter, reducer, and booster into a lighter, more compact assembly. Enhanced noise isolation and vibration damping further elevate cabin comfort. By combining unique cold spray valve seat technology, outstanding engine thermal efficiency, and advanced hybrid architecture, Nissan is poised to deliver a new standard in electrified mobility for mainstream consumers.
