Research project to deliver certified laser repairs for military aircraft components

An industry-led research collaboration is set to transform how Australia maintains its most critical defence aircraft — shifting from costly and long lead-time component replacement to certified, high-performance laser repair. Supported by the Additive Manufacturing Cooperative Research Centre (AMCRC), the two-year collaboration brings together Rosebank Engineering, RMIT Centre for Additive Manufacturing and Swinburne University of Technology to develop a certifiable Laser Direct Energy Deposition (L-DED) repair process for high-value aerospace alloys used broadly across modern military aircraft. The research focuses on precipitation-hardening materials widely used in defence aviation, including Inconel, Titanium, and 15-5PH stainless steel, with the goal of demonstrating the repair of an advanced military aircraft component in line with Original Equipment Manufacturer (OEM) and NASA-STD-6030 requirements. At the core of the project is an innovative laser rescanning technique designed to control microstructure during the repair process itself. By tailoring heat input locally, the team aims to achieve the required material property performance without post-process heat treatment — a major barrier to qualifying additive repairs in aerospace. Rosebank Engineering will lead process development and validation, integrating its unique Adaptive Monitoring and Control of Laser Additive Deposition (AMCLAD) system to ensure consistent and repeatable repair outcomes. Jarrod Watts, Senior Manager Engineering and Projects, at Rosebank Engineering said the project is a substantial step toward achieving certified laser repairs of high-value high-strength steel components. “These types of high-value components are currently sourced – in the sustainment environment – from complex international supply chains with long lead-times. We know laser offers the opportunity to repair in-country with significant cost and lead-time reductions. This project tackles that challenge directly”, Watts said. “Through the use of our AMCLAD capability, and in-process refinement of the microstructure, we can deliver material performance that meets aerospace requirements without risking distortion or damage of the original component. Developing the ability to reliably repair critical components in-country mitigates supply chain risks, reduces cost of ownership for our customers and enhances operational readiness.” Researchers at RMIT Centre for Additive Manufacturing and Swinburne University of Technology will generate the technical evidence supporting qualification, including tensile strength, fatigue life, residual stress, corrosion and wear performance, forming a comprehensive Material Property Suite aligned with NASA standards. Professor Milan Brandt of RMIT Centre for Additive Manufacturing, overseeing the laser process optimisation, said the project pushes additive process control into new territory. “Laser rescanning allows us to refine microstructures in ways conventional heat treatment cannot achieve in repair scenarios. By controlling phase transformations during deposition, we can unlock performance levels that meet aerospace standards,” Professor Brandt said. Swinburne University of Technology will undertake detailed material characterisation and mechanical testing as part of the project. Professor Suresh Palanisamy of Swinburne University of Technology underlines the importance of rigorous validation to industry adoption. “Certification is evidence-driven. Our role is to produce the data that proves the process is robust, repeatable and capable of meeting aerospace requirements. That depth of validation is what enables industry confidence”, Professor Palanisamy said. The project will also explore repair pathways for in-demand F/A-18 engine components, providing a near-term commercial opportunity that equally supports broader adoption across a broad family of aircraft. Simon Marriott, Managing Director of AMCRC, said the project reflects the CRC’s industry-first focus. “Australia has strong additive manufacturing research capability. AMCRC exists to translate that strength into commercial and defence outcomes”, Marriott said. “This project exemplifies that mission — industry-led, defence-relevant, and built around certification from day one. By enabling certified local repair, we strengthen sovereign manufacturing capability and deliver long-term economic and strategic benefit.” For Editorial Inquiries Contact: Editor Kym Bergmann at [email protected] For Advertising Inquiries Contact: Group Sales Director Simon Hadfield at [email protected]