Ali Bakir's Research: Impactful Aerospace Repair Innovations

Thu, 05 September, 2024

Delve into Ali Bakir's pioneering research on cold spray technology and its transformative impact on the aerospace industry

Ali Bakir, a PhD candidate at the National Structural Integrity Research Centre (NSIRC) and now an engineer at TWI, has developed innovative methods for assessing and repairing high-strength aluminium 7075 components.

This article offers a comprehensive overview of his research, detailing how it overcomes traditional repair challenges and the crucial role his experience at TWI has played in aligning academic breakthroughs with industrial needs.

Awarded by Coventry University and sponsored by Lloyd's Register Foundation, Ali’s PhD research focuses on the structural assessment of aluminium 7075 components repaired using cold spray technology. This method deposits metal particles at high velocity to create a durable repair surface. Given aluminium 7075's critical role in aerospace applications due to its strength, traditional repair methods have been costly and time-consuming. Dr. Bakir’s work provides a promising alternative by addressing concerns about the structural integrity of these repairs under various loading conditions. His findings validate cold spray technology for industrial use, offering a more efficient and cost-effective solution.

The aerospace industry faces substantial costs and delays associated with replacing damaged components. Cold spray technology could alleviate these challenges by providing a reliable repair method that reduces downtime and costs. Ali's research focuses on certifying the cold spray repair process for aluminium 7075, potentially leading to more sustainable operations within the sector.

Throughout his PhD, Ali encountered challenges, particularly in demonstrating the tensile performance of repaired specimens. To address this, he collaborated with Coventry and Southampton universities, conducting additional testing that supported his findings. This interdisciplinary approach not only enhanced his research but also highlighted the importance of collaboration in solving complex engineering problems.

Ali's experience at NSIRC and TWI was instrumental in shaping his research and professional development. His work at TWI provided hands-on experience with industry standards and experimental methods, facilitating a smooth transition from academia to industry. Collaborating with experts in structural assessment, coating technologies, and failure investigation, refined his research and ensured its practical relevance.

The industrial impact of Ali’s research is significant. By offering a cost-effective and reliable repair method, his work on cold spray technology addresses a critical need in the aerospace sector. Certifying cold spray as a dependable repair method could lead to its widespread adoption, reducing costs and extending the lifespan of essential aerospace components.

Since completing his PhD, Ali has seamlessly transitioned into a full-time role at TWI, applying his academic knowledge to real-world industrial challenges. His research remains highly relevant, demonstrating the effective integration of academic research with practical application.

Ali’s journey from PhD student to TWI engineer exemplifies the powerful synergy between academic innovation and industrial application. His work on cold spray technology holds the potential to significantly reduce repair costs and enhance the efficiency of high-strength aluminium components, leaving a lasting impact on the aerospace industry and beyond.