Development, Validation and Inspection of Metallic Repairs

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 36729

Start date and planned duration: January 2026, 36 months

Objective

To develop a guidance on repair process selection, including technical advantages, limitations, and economic considerations
To develop and improve advanced repair methods for high value metallic[PM1.1] components

Project Outline

For dimensional restoration and repair of high value metallic components, there are a range of processes available, each suited to different materials, dimensional tolerances, component complexity, and end use operating environments. However, there is currently limited guidance and consensus on the appropriate selection of repair processes for specific application.

This project will address this issue, beginning with a comprehensive review of existing dimensional repair/restoration methods and technologies, in order to provide data driven guidance on repair process selection. This shall include the technical advantages, limitations, and economic considerations of each approach.

This review shall also highlight knowledge or capability gaps, to identify areas for development necessary to enable dimensional repair of more challenging or complex scenarios. Selected repair processes will be developed for higher performance requirements, greater process resolution, and to address material compatibility challenges that limit adoption.

Industry Sectors

- Aerospace

- Defence

- Energy

- Manufacturing

- Engineering and maintenance

Benefits to Industry

Industry interest in improved repair capability is strong and immediate, driven by the need to increase asset availability, reduce maintenance costs, and minimise component wastage. This project addresses key barriers to the adoption of advanced repair technologies, enabling greater industry engagement and accelerating implementation.

The proposed work will support reductions in maintenance and replacement costs, through the development of improved repair processes that extend the service life of repaired components. The project will also increase industrial confidence in the consistency and reliability of repaired components, through the integration and implementation of advanced process monitoring and inspection techniques.

In addition to commercial benefits, the project also aligns with the Net Zero objectives by developing and validating repair processes which may contribute to reduced material consumption, minimising waste generation, and lowering the environmental impact associated with component replacement. The outcomes will support the wider adoption of advanced repair technologies, leading to improved industrial productivity, enhanced sustainability, and greater long-term economic value across various industries.