AbstractFriction surfacing is a solid-state surface engineering technology. Previous studies have shown that underwater friction surfacing has some advantages in efficiency and homogeneity of the deposited material. To use these advantages a water spray cooling system was implemented to achieve a more flexible process. This concept has been investigated by depositing Al alloy AA6082 T6 on AA2024 T351 substrate. The efficiency of the process was increased from 19% to 31% without influencing the properties of the deposited material. Temperature measurements revealed that the intensity and chosen location of cooling also affect the process characteristics and allow modifying the coating geometry.