Engineer Research and Development Center News Releases

John H. Overton Lock and Dam, Red River: Lower Navigation Approach Physical Model

Press Operations — Fri, 13 Mar 2026 17:42:00 GMT

Abstract: The US Army Engineer Research and Development Center, Coastal and Hydraulics Laboratory (ERDC-CHL) conducted a physical model study of the John H. Overton Lock and Dam to optimize the navigation conditions in the lower lock approach. ERDC built a 1:100 Froude scale model to evaluate the navigation conditions for tows entering and exiting the lower lock approach. The final design consisted of two submerged rock dikes implemented approximately 1,500 and 3,000 ft downstream of the dam’s crest. The larger submerged rock dike was parallel to the channel, located in a scoured area at the downstream end of the riprap channel bed, and contained a crest elevation of approximately 15 ft, North American Vertical Datum of 1988 (NAVD 88). The smaller submerged rock dike extended from the most upstream end of the first rock dike, diagonally crossing the channel to the right-descending bank, and contained a crest elevation of approximately 30 ft, NAVD 88. The model provided data regarding tow tracks, current direction, and velocity information for various possible optimizations to the dam’s lower lock approach.

Enhanced Spatial Resolution of Landsat Imagery Through Systematic Sensor Offset Exploitation: A Blended Pansharpening Approach

Press Operations — Tue, 03 Mar 2026 21:20:00 GMT

Purpose: This technical note presents a novel blended pansharpening methodology that exploits the systematic 7.5-meter (m) geometric offset between Landsat multispectral (MS) and panchromatic (pan) sensors to achieve selective spatial enhancement beyond conventional 15 m resolution limits. The approach creates a variable resolution product with an effective resolution of approximately 11.25 m and demonstrates superior spatial detail preservation in urban infrastructure while maintaining perfect spectral integrity.

The Use of Nitrocellulose Production Waste for Energy Generation

Press Operations — Tue, 03 Mar 2026 21:18:00 GMT

Abstract: The US Army Engineer Research and Development Center investigated the use of nitrocellulose (NC) fines, an ammunition waste, for energy generation. NC is a natural high polymer obtained from treating cotton or wool with nitric and sulfuric acid. It is widely used in the industry, with military applications being the largest use currently. Since military applications range from bullet propellants to missiles for tube munitions, large quantities must be produced to meet the demand. However, large NC production batches result in large quantities of NC fines waste, generated in the form of insoluble fibers in suspension in wastewater after manufacturing. Hence, a method to reuse this generated waste and convert it into energy was tested. This study evaluated the potential of creating energy from NC waste through hydrothermal liquefaction and gasification of NC, yielding methane (CH4) as the final product. Results demonstrated that the CH4 concentrations increased as the temperature, reaction time, and catalyst addition were increased, yielding a maximum concentration of 2,000 ppm (6,400 peak area of the chromatograph). The homogenous catalyst performed better than the heterogenous catalyst, since it increased the CH4 yield up to 6 times the concentration obtained with no catalyst added.

Overview of PFAS in Aquatic Environments

Press Operations — Tue, 03 Mar 2026 21:16:00 GMT

Abstract: PFAS are highly stable fluorinated compounds with unique properties and are used in a broad array of industrial processes and commercial products. PFAS are extremely recalcitrant and are widespread in the environment, with measurable concentrations in soils, sediments, groundwater, surface water, and rainwater, even at sites far removed from known sources or releases. Select PFAS (especially longer-chain perfluorinated carboxylic and sulfonic acids) are known to bioaccumulate in aquatic food webs, presenting potential risk to higher trophic species, including hu-mans. Evidence suggests sediment serves as a repository and potential ongoing source for many of these long-chain PFAS. The global presence and persistence of PFAS pose a fundamental challenge to addressing potential effects on environmental quality and health. The public and policymakers are increasingly concerned about the potential presence and effects of PFAS in water and sediments. This concern includes knowledge gaps for dredged material management, posing challenges to execution of the US Army Corps of Engineers Civil Works navigation program. This document provides a comprehensive review of PFAS in the aquatic environment based on published studies and includes overviews of chemical classifications, regulatory considerations, historical uses and sources, environmental distribution, fate and transport pathways, and uptake and effects in aquatic organisms.

AIS Analysis of Waterway Utilization Based on Vessel Type and Class

Press Operations — Wed, 25 Feb 2026 21:32:00 GMT

Abstract: The purpose of this technical note (TN) is to provide an overview of a method used to classify waterway segments based on remotely-sensed vessel traffic on those waterway segments. Vessel traffic was evaluated using data from Automatic Identification System (AIS) broadcasts, which originate at transceivers onboard vessels and can be received by terrestrial shore sites or satellites. AIS is used by most ocean-going commercial vessels, while use by inland vessels varies according to domestic regulations.

Ice Cutting and Removal for Cold Weather Improved Ribbon Bridge (IRB) Crossings

Press Operations — Mon, 23 Feb 2026 21:38:00 GMT

Frozen rivers provide an obstacle for any military force, as ice impedes the use of Improved Ribbon Bridges (IRBs) or other bridging vehicles. Finding an efficient way to cut and remove ice to allow for the emplacement of bridging assets is critical. The US Army Cold Regions Research and Engineering Laboratory’s (CRREL) Cold Weather IRB team went to Camp Grafton, North Dakota, to collect data for the North Dakota National Guard who were conducting a frozen wet gap crossing in February of 2022. Both quantitative and qualitative data were collected to evaluate strategies for ice cutting, removal, and IRB placement. After ice cutting and removal, an IRB bay was successfully placed in the frozen pond. Laboratory tests were conducted in March 2022 to examine different chainsaw chains for cutting an ice sheet grown in the Geophysical Research Facility (GRF) at CRREL. Chainsaws were determined to be an effective tool for cutting ice, and the speed and comfortability of different chains were documented. The data collected from this project will help to drive the North Dakota National Guard creation of a winter bridging course and will be used to update the Army’s Tactics Techniques and Procedures (TTPs) for cold weather bridging operations.

Demonstration Validation of Industrial Supercritical Water Oxidation (iSCWO) PFAS Destruction Technology: Aqueous Film-Forming Foam Treatment by General Atomics (GA) iSCWO System

Press Operations — Fri, 20 Feb 2026 21:45:00 GMT

Abstract: The Department of Defense (DoD) is confronted with a pressing environmental challenge concerning legacy aqueous film-forming foam (AFFF) concentrate, historically used in firefighting activities. Legacy AFFF contains PFAS, which are identified as persistent environmental contaminants associated with adverse health effects. Considering increasing environmental regulations and concerns regarding human health impacts, the DoD needs to properly destroy legacy AFFF. The US Army Engineer Research and Development Center (ERDC) led a project focused on the demonstration and validation of technologies for the destruction of PFAS in AFFF. Results are presented for the treatment of 100 gal. of AFFF using the General Atomics industrial Supercritical Water Oxidation system. The demonstration showed destruction removal efficiencies (DREs) for total PFAS analyzed via total oxidizable precursor (TOP) assay (S24 PFAS), ranging from 98.5% to 99.9991%. No volatile fluorinated compounds were detected in the stack emissions as analyzed via Other Test Method 50; however, up to 6,000 ppt S51 PFAS as analyzed via TOP assay was detected in demister effluent. The energy consumed per cubic meter of AFFF and order of magnitude S24 PFAS destroyed ranged from 2 to 24 MWh, while the energy consumed per gram of S24 PFAS destroyed ranged from 0.046 to 48 MWh.

Overview of the Coastal Storm Model Development and Results for the Deer Island Restoration Study Using the Engineering With Nature® Toolkit

Press Operations — Fri, 20 Feb 2026 21:43:00 GMT

Abstract: The Coastal and Hydraulics Laboratory of the US Army Engineer Research and Development Center presents this study as a comprehensive numerical model development and validation approach that can be employed to simulate winds, waves, and water levels during significant storm events for the Deer Island Restoration Project in Mississippi. Leveraging validated storms from the South Atlantic Coastal Study, this research utilized the Coastal Storm Modeling System with the coupled Advanced Circulation (ADCIRC) and Steady-State Spectral Wave (STWAVE) models. As part of this effort, the ADCIRC mesh was updated to encompass the Deer Island region and two variations on elevated water level scenarios were incorporated. Specifically, 10 validated storms were simulated, with varying sea-level conditions, to represent a range of feasibility-level proxy events from a 1- to 10,000-year annual exceedance frequency. The modeling outcomes provide a detailed depiction of water levels, wave heights, and storm surge impacts on Deer Island under different sea-level rise scenarios. These results offer critical insights into the potential effects of the restoration project on Deer Island and the surrounding areas. The findings can inform decision-makers and contribute to formulating effective guidelines for restoration projects within the Mississippi region and in coastal areas facing similar challenges worldwide.

Infection Risk Assessment for Socially Structured Population Using Stochastic Microexposure Model

Press Operations — Wed, 18 Feb 2026 21:53:00 GMT

Abstract: Predicting infection outbreak dynamics within local microenvironments is a challenging task. Some methods assume smaller population pools and often lack the statistical power of inferences. Others are designed for larger population pools and cannot be downscaled to accommodate the details of microenvironments. Practicable infection risk assessment models should account for population size, geometry and occupancy of public places, behavioral and professional patterns of daily routines, and societal structure. This study is based on the stochastic microexposure model, which has been generalized to describe clustered populations. The methodology is demonstrated for a community of several thousand students on campus. The results indicate the social structure has the ﬁrst order effect on the spread of the infection. Depending on the number, size, and degree of inner- and outer-cluster connections, the outbreak exhibits distinct durations, power, and multiple peaks of infection. Moreover, the contribution of different microenvironments to infection risk evolves during the course of the outbreak. Social structure plays a major role in infection spread and should be accounted for in risk prediction tools. The stochastic microexposure model accounts for the social structure of a population at multiple scales and can predict the dynamic contributions of different microenvironments to infection spread risks.

Mesh Convergence Study of Adaptive Hydraulics (AdH) Version 5.9

Press Operations — Wed, 18 Feb 2026 21:50:00 GMT

Abstract: This report details performance and convergence tests of the Adaptive Hydraulics (AdH) v5.9 software suite on the Engineer Research and Development Center ONYX Cray X40/50 supercomputer. In particular, the performance of a recently developed monolithic model coupling AdH framework between the Richards equation for variable groundwater and surface water flows or for overland sloped conditions is studied. The effort is part of a quality assurance test of a recently restructured version of AdH. The report also includes a scalability analysis of AdH on a Cray system.

Publications of the US Army Engineer Research and Development Center : Appendix J : FY25 (October 2024–September 2025)

Press Operations — Wed, 18 Feb 2026 21:48:00 GMT

Abstract: Each year, the US Army Engineer Research and Development Center (ERDC) publishes more than 200 reports through the Information Technology Laboratory’s Information Science and Knowledge Management (ISKM) Branch, the publishing authority for ERDC. Annually since 2017, ISKM has compiled a list of the previous fiscal year’s publications. This Appendix J to the original collection includes ERDC publications issued October 2024 through September 2025. The publications are grouped according to the technical laboratories or technical program for which they were prepared, and the preface includes procedures for obtaining ERDC reports. Through this compilation, online distribution, and physical collections, ISKM continues to support ERDC, the Army, and the nation.

Modeling the Service Life of Temporary Airfield Operational Surfaces Under Multi-Pass Aircraft Trafficking

Press Operations — Wed, 18 Feb 2026 21:46:00 GMT

Abstract: Expeditionary Airﬁeld (EAF) surfacing systems are designed to create temporary aircraft operating surfaces. Modeling the service life of EAF surfacing systems including the matting system, aircraft, and subgrade, has historically proven difﬁcult, exacerbated by variability between systems and the multitude of mechanisms that can constitute failure. The study presented herein outlines the development and implementation of a performance modeling approach that includes a multi-scale scheme that accounts for local characteristics of the connection points of the EAF matting system, coupled to the global characteristics of the matting array to predict cyclic passes to failure. Finite element studies were conducted for an EAF surfacing system brickwork conﬁguration subjected to aircraft strut loads over varying California Bearing Ratio (CBR) subgrades to calibrate a transfer function to full-scale trafﬁcking experiments. The proposed framework is then used to predict the rate of subgrade deformation for additional lay patterns, which successfully ranked the performance of each relative to full-scale trafﬁcking experiments. An approach is proposed to couple the rate of subgrade deformation with local ﬁnite element models to capture increasing joint damage as permanent deformation accumulates, and supplemented by a variable amplitude cycle counting and damage accumulation algorithm that yields reasonable agreement with full-scale experiments while capturing the transition in failure mechanisms at higher CBR values. The results of the study presented herein captures the propensity for end connector and subgrade failure over a range of subgrade CBRs and shows promise for a broader performance framework that can be extended to other EAF surfacing systems, aircraft types, and speciﬁc matting lay patterns.

Civil Works Megaprojects: Cognitive Biases and Lessons for Effective Risk Mitigation

Press Operations — Wed, 18 Feb 2026 13:52:00 GMT

Abstract: U.S. Army Corps of Engineers (USACE) megaprojects are critical infrastructure investments that often experience cost overruns, schedule delays, and performance issues, with over 35 % of USACE dam structures rated in poor condition. This paper presents the ﬁrst quantitative case study of past USACE Lock and Dam megaprojects—including the Charleroi, Chickamauga, Olmsted, Soo, and Montgomery projects —to identify patterns of risk mismanagement that contribute to these challenges. Using Bayesian methods and quantitative analysis on the risk registers of these projects, the study demonstrates that over-optimism in initial risk assessments, particularly the underestimation of risk likelihoods, can diminish the effectiveness of subsequent mitigation efforts by 25 % on average. The analysis also ﬁnds that risk managers tend to prioritize mitigation for risks where their conﬁdence in assessment is highest, leaving higher-uncertainty risks less addressed. Based on these ﬁndings, the paper offers evidence-based recommendations for implementing structured risk governance frameworks, such as reference-class forecasting and external risk validation. This study advances project management knowledge by providing the ﬁrst quantitative evidence of cognitive biases shaping risk register practices in civil works megaprojects. Incorporating such insights into future risk assessment and decision support methods can support critical infrastructure management and performance.

Advancing Multi-Scale Wave Modeling: Global and Coastal Applications During the 2022 Atlantic Hurricane Season

Press Operations — Tue, 17 Feb 2026 16:10:00 GMT

Abstract: Using the six-month hurricane season of 2022 as a case study and the spectral wave model WAVEWATCH III, this effort shows that wave parameters produced via a variable-resolution global mesh (5–30 km) agree with a diverse array of validating observational datasets at a level comparable to that of a constant-resolution mesh (3 km) that is six times more costly to run. The optimized variable-resolution, unstructured triangular mesh is faithful to land geometry and wave transformation gradients while relaxing focus in deeper regions where gradients are typically less pronounced. Wave parameters measured via satellite altimetry, stationary buoy networks, and drifting buoys are employed to demonstrate not only a substantial increase in performance over a coarse, constant-resolution grid (40 km), with RMSE reduced from 0.28 m to 0.14 m and Correlation Coefficient (CC) improved from 0.92 to 0.98 overall, but also a comparable level of performance to that of a mesh that has undergone a full convergence analysis. Performance comparisons isolated to shallow regions and near cyclonic storms highlight the importance of resolving relevant geometries. For nearshore data, RMSE improves from 0.29 m to 0.13 m and CC from 0.89 to 0.98; in shallow regions, RMSE from 0.29 m to 0.15 m and CC from 0.88 to 0.97; and under cyclonic conditions, RMSE from 0.62 m to 0.35 m and CC from 0.93 to 0.98. Wave model results using the variable-resolution mesh were further analyzed to provide a detailed summary of the wave climate, including wind-wave and swell partitions, over the six-month study period in the study area.

Morphology-Driven Electromagnetic Shielding Performance of Graphitic Nanoparticles in Segregated Polypropylene Nanocomposites via Electromagnetic Melt Processing

Press Operations — Fri, 13 Feb 2026 21:29:00 GMT

Abstract: Electromagnetic melt-processing has emerged as an innovative and energy-efﬁcient strategy for the structuring of thermoplastic nanocomposites. In this study, polypropylene (PP)-based TPNCs were fabricated using different grades of graphitic carbon nanoparticles to yield electrical conductivity and electromagnetic interference shielding effectiveness. The applied structuring methodology consists of a multiscale processing strategy that combines high-energy ball milling of polymer micro-pellets and CNPs, formulated powder compaction into green bodies, and EM-driven localized heating to produce the TPNCs. This enables the formation of highly segregated, percolated conductive networks at ultra-low ﬁller loadings. The percolation threshold values for green bodies were signiﬁcantly dependent on CNP morphology, ranging from approximately 0.50 wt% for low-aspect-ratio graphene nanoplatelets to around 1.0 wt% for medium-aspect-ratio carbon nanotubes. Upon EM melt-processing, due to viscoelastic deformation of CNP networks, the resulting threshold values of the structured TPNCs were approximately 0.73 wt%, 0.50 wt%, and 0.74 wt% for low, medium, and high aspect ratios, respectively. High-aspect-ratio CNTs, despite exhibiting greater structural defects, achieved the highest EMI SE of 19.7 dB/mm at 10 wt%, demonstrating that morphology dominates over graphitic crystallinity in governing transport properties and electromagnetic performance. Statistical modeling via response surface methodology conﬁrmed the predictive signiﬁcance of the CNP morphology and the concentration responses. This work underscores the critical inﬂuence of ﬁller architecture and EM-induced structuring in enabling a novel, scalable platform for multifunctional polymer nanocomposites with enhanced electromagnetic shielding capabilities, offering promise for next-generation aerospace, electronics, automotive, and defense applications.

Standalone Color-Based Bathymetry Over 10 Years at Duck (NC, USA) from Optical Satellite Imagery and Wave Breaking Analysis

Press Operations — Fri, 13 Feb 2026 19:37:00 GMT

Abstract: Coastal hazard forecasting and morphological modeling rely on having accurate and up-to-date nearshore bathymetry. Traditional methods provide high precision but are expensive, complex to deploy, and only cover limited areas, leaving many coastal regions unmapped or under surveyed. In this context, Satellite-Derived Bathymetry provides a more accessible and scalable alternative, enabling frequent and global observations of the nearshore zone. This study applies the color-based log-band ratio method to extract nearshore bathymetry at Duck, North Carolina, a highly dynamic environment with a wide range of turbidity values and wave breaking extents. The log-band ratio method is an empirical approach for estimating shallow-water depths from multispectral satellite imagery which relies on the natural attenuation of light in water column, where the ratio of two spectral bands is logarithmically related to water depth. Unlike traditional SDB approaches, this method relies only on nearshore in situ wave height data, using satellite-detected breaking positions and breaker height-to-depth ratio as depth calibration points. Additionally, an automated approach is used to select images where the green/blue band penetrates sufficiently into the water to retrieve bathymetry avoiding the subjectivity of traditional manual selection. The method is validated through alongshore median- and profile-based assessments, yielding a median RMSE of ∼60 cm. Sensitivity tests on key parameters, including the breaker height-to-depth ratio and the calibration time window, demonstrate that a constant breaker height-to-depth ratio provides reliable results and that a significant number of calibration points is necessary for accurate bathymetry retrieval. This approach retrieves instant bathymetries and allows for the extraction of bathymetry evolution over time, with 90 bathymetry maps available over the 10-year period due to the very high resolution and 2-day revisit VEN𝜇S satellite and the 10-m/5-day Sentinel-2 mission. The method is transferable to other optical satellites such as Landsat, although it should be applied with caution, enabling long-term nearshore bathymetry monitoring from the 1980s to the present.

Evaluating Freshwater Mussel Sampling Methodologies Using a Simulation Model

Press Operations — Fri, 13 Feb 2026 19:35:00 GMT

Abstract: Field surveys form the basis of many research efforts and are the foundation for estimates of population size and density that inform conservation and management practices for imperiled species. As a result, evaluating the performance of different survey methods across a range of conditions that may be encountered in the ﬁeld can increase understanding of the time and effort that may be required to ensure that survey results are sufﬁciently accurate and reliable for conservation goals. We used a spatially explicit agent-based model to simulate four commonly used freshwater mussel ﬁeld survey methodologies: simple random sampling (SRS), transect random sampling (TRS), adaptive cluster sampling (ACS), and qualitative timed searches (QTS) to investigate the inﬂuence of sampling method, spatial distribution, and mussel density on the performance (i.e., accuracy, precision, and detection rate) of survey techniques. Our analysis suggests that mussel density, spatial distribution, and sampling effort inﬂuence sampling accuracy, precision, and species detection for all sampling methods. QTS produces highly variable catch-per-unit-effort (CPUE) metrics when mussels are dense and/or clustered, indicating the technique may be unreliable as a proxy for density. Quantitative methods like SRS and TRS may be well-suited for estimating population characteristics, but a high level of effort may be needed to obtain reasonable accuracy when mussels occur at low densities. ACS may be more efﬁcient for mussels at low densities, but it can be challenging to plan for the level of effort required to complete an ACS protocol. Designing an ecological survey requires careful consideration of research objectives and available resources. Future research may consider the performance of qualitative and quantitative surveys in combination as a means of overcoming some of the practical challenges of applying individual survey methods.

Numerical Study of Submergence-Induced Forces on a Maintenance Bridge

Press Operations — Thu, 12 Feb 2026 19:52:00 GMT

Abstract: The US Army Engineer Research and Development Center–Coastal and Hydraulics Laboratory conducted a numerical study for a proposed maintenance bridge over the Trinity River in downtown Fort Worth, Texas, that will be submerged in flood conditions. The purpose of this study was to determine the hydrodynamic loads on the structure. The study found that, due to a combination of peak velocities and water depth, a return period of 500 yr generates the largest drag forces, while the higher depth and discharge of the standard project flood generate larger lift forces. Two flow structures were observed with shallow submergence: The first resulted in a jet parallel to the deck with a recirculation extending from railing to railing and the second resulted in a plunging jet over the deck with smaller but stronger recirculation. These patterns resulted in significantly different loads on the structure. The study analyzed the bridge’s deck slope to the flow as a possible variable affecting the loads. Observed changes related mostly to the flow pattern predicted for different flow configurations. Finally, it was observed that an open railing provides the best possible conditions in terms of loading; therefore, minimizing the frontal area of the railing is recommended.

Investigation of Graphene Nanoplatelets for Adsorptive Removal of Aqueous Munitions Compounds 2,4,6-Trinitrotoluene (TNT) and Hexahydro-1,3,5-Trinitro-S-Triazine (RDX)

Press Operations — Thu, 12 Feb 2026 19:50:00 GMT

Abstract: Graphene nanoplatelets (GnPs) were evaluated against munitions compounds 2,4,6-trinitrotoluene (TNT) and hexahydro-1,3,5-trinitro-s-triazine (RDX) in aqueous solutions for adsorptive removal performance. Fourier transform infrared and Raman spectroscopy were employed to characterize samples and inform adsorption mechanisms. Adsorption kinetics and isotherm studies were conducted in deionized water and compared with granular activated carbon (GAC). Evaluations were conducted with varying pH levels, ionic strengths, and temperatures and with surface water solutions to assess the impact of environmental factors on performance and further inform adsorption mechanisms. This study demonstrated that GnPs exhibited more rapid adsorption than GAC. Furthermore, TNT was adsorbed with greater capacity by GnPs compared to GAC, while GnPs removed RDX in greater capacity only when results were normalized for surface area. The more planar structure of GnPs may have contributed to performance enhancements relative to GAC. Adsorption was not impacted by variations in pH or ionic strength, indicating stable performance in different environments. Thermodynamic analysis indicated that removal was more favorable at higher temperatures. Furthermore, π-π interactions likely facilitated TNT removal by GnPs, while RDX was removed through physisorption by van der Waals forces. This study advanced understanding of environmental management of munitions compounds, as the adsorptive performance of GnPs for munitions compounds in solutions within a natural environmental matrix were evaluated, and key mechanisms supporting adsorptive removal of these compounds were informed. Overall, this study demonstrated the effectiveness of GnPs in treating water contaminated with TNT or RDX, particularly when rapid adsorption is preferred.

Mechanical Properties and Microstructure of Annealed Ni/CrC-NiCr Metal Matrix Composite Prepared by Cold Sprayed Deposition

Press Operations — Thu, 12 Feb 2026 17:37:00 GMT

Abstract: This study investigates the effects of low (700 ◦C) and high (1000 ◦C) temperature annealing on the micro-structure and mechanical properties of two metal matrix composites consisting of Ni and two separate compositions of CrC-NiCr cold-sprayed onto A-514 structure steel. The mechanical properties, including tensile strength, ductility, interface shear strength, and microhardness, were evaluated after heat treatments. Additionally, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), and transmission electron microscopy (TEM) were used to characterize the microstructure of the annealed deposits. The results showed that annealing signiﬁcantly enhanced the inter-splat bonding quality between the matrix (nickel) particles. However, higher temperature annealing led to an increase in voids surrounding the cermet particle due to enhanced elemental diffusion. Furthermore, the interparticle bonding between the nickel particles in the matrix and the cermet particle was also improved after annealing. Depending on the composition, the ultimate tensile strength increased by a minimum of 32 %, and the adhesion shear strength improved by over 77 % following annealing at 1000 ◦C. Recrystallization and reduction of the dislocation density in the nickel matrix occurred within the splats during annealing, resulting in increased ductility from less than 0.2 % in the as sprayed condition to more than 6.5 % after annealing. However, a general reduction in hardness was observed after annealing. The interplay between the annealing temperature, microstructural evolution, and mechanical performance demonstrates that the improved bonding directly inﬂuenced the mechanical properties, resulting in increased tensile strength, greater ductility, and a shift from brittle to ductile fracture behavior as the micro-structure evolved.