Australia develops laser repair technology for military aircraft

An Australian research collaboration is developing a laser-based repair process for high-value military aircraft components, such as fighter jets. The two-year project aims to reduce reliance on international supply chains and long lead times by enabling in-country repairs rather than costly component replacements.

The initiative, supported by the Additive Manufacturing Cooperative Research Centre (AMCRC), brings together Rosebank Engineering, the RMIT Centre for Additive Manufacturing, and Swinburne University of Technology. The team is working to develop a certifiable Laser Direct Energy Deposition (L-DED) process for aerospace alloys, including titanium, Inconel, and 15-5PH stainless steel.

A key focus of the research is a laser rescanning technique designed to control material microstructure during the repair process. This method aims to meet Original Equipment Manufacturer (OEM) and NASA-STD-6030 requirements without the need for post-process heat treatment, which has historically been a barrier to qualifying additive repairs in the aerospace sector.