Product Code: ICA11_503

Potential Application and Certification of Laser Cladding Technology for Repair of Ageing Aircraft Components
Authors:
Qianchu Liu, Defence Science and Technology Organisation (DSTO), Defence Materials Technology Centre (DMTC); Fishermans Bend Australia
Milan Brandt, RMIT University, Defence Materials Technology Centre (DMTC); Bundoora Australia
Madabhushi Janardhana, Aircraft Structural Integrity Section, DGTA, Royal Australian Air Force (RAAF); Laverton Australia
Ryan Cottam, Swinburne University of Technology, Defence Materials Technology Centre (DMTC); Melbourne Australia
Neil Matthews, Rosebank Engineering Pty Ltd., Defence Materials Technology Centre (DMTC); Melbourne Australia
Peter Khan Sharp, Defence Science and Technology Organisation (DSTO); Fishermans Bend Australia
Presented at ICALEO 2011

In-service damage from corrosion, wear or debris impact are increasingly common with ageing military aircraft fleets. Maintenance of this type of ageing damage can be expensive and have significant impact on fleet availability. DSTO is looking at a number of surface modification or repair technologies that can be used on an opportunity basis to restore geometry or restore the life of an aircraft component. The basis of the technology selection was that there should be no risk with the technology, and the challenge is in developing an approved process for the application to aircraft. With the advent of small high powered lasers, laser cladding (LC) is one of the surface modification technologies examined. It uses a high-powered laser beam to melt a deposited layer of material onto a substrate. LC could offer significant cost saving, as a repair alternative to the replacement of damaged components due to its relatively low heat input, flexibility, high variety of filler materials and ease of automation. The Defence Science and Technology Organisation, and Defence Materials and Technology Centre, Australia, have demonstrated that laser cladding technology could potentially be used to repair or refurbish damaged components. This paper briefly summarises the current research work on laser cladding of 7xxx series aluminum alloys and discusses potential application and technology certification for repair of aircraft components in the near future.