Laser repair enhancement for Aero Engine components
Business challenge
Process Innovation
Sector
Aerospace
Technology or capability
Laser Processing
Additive Manufacturing
Automation & Robotics
Optimising surface pre-and post-heating for aerospace applications
MTC collaborated with Rolls-Royce to validate an innovative heat treatment solution using Vertical Cavity Surface Emitting Laser (VCSEL) technology. This approach aims to improve aero engine repair processes by delivering precise and stable surface heating for welding and directed energy deposition (DED) applications.
The Challenge
The aerospace sector faces increasing demand for through-life engineering services, projected to reach $2.5 trillion over the next 20 years. Maximising engine uptime and reliability is critical for profitability. However, current repair capabilities are limited by inefficient pre- and post-heat treatment processes and a constrained supply chain, impacting maintenance strategies for next-generation low-emission engines.
MTC's Solution
- Conducted a detailed investigation of VCSEL technology as a heat treatment tool for welding and DED repair of aero engine components.
- Performed temperature profiling and heating area analysis using advanced sensors.
- Achieved stable heating conditions with ±1°C variation, covering a maximum effective heating area of 145 x 20 mm and a minimum of 8 x 10 mm.
- Validated VCSEL’s capability to heat both cast and polished metal surfaces with high precision.
The initial trials conducted by the MTC using VCSEL-based surface heating have demonstrated encouraging potential for improving aero engine repair processes. While the technology is still at an early stage, these results provide a foundation for further investigation and development as we assess its suitability for future applications.
Chris Heason, Associate Fellow – Repair & Overhaul Technology, Rolls-Royce
The Outcome
The project successfully demonstrated VCSEL-based surface heating as a viable solution for enhancing aero engine repair techniques. This innovation supports low Technology Readiness Level (TRL) exploration, enabling Rolls-Royce to adopt advanced manufacturing technologies for improved maintenance and repair processes.
Benefits to the Client
- Enhanced laser welding and DED repair processes through precise, controllable surface heat treatment.
- Reduced waste and improved sustainability credentials via component remanufacturing.
- Increased market share and profitability by minimising engine downtime.
- Delivered a robust technique capable of heating diverse metal surfaces, improving repair flexibility.
This project highlights the MTC’s ability to deliver innovative process solutions at low TRL, enabling our clients to explore advanced manufacturing technologies. The successful validation of VCSEL surface heating for both cast and polished metals is an important step towards enhancing repair techniques in the aerospace sector.
Bethan Smith, Technology Manager - MTC