Corrosion is a constant threat to the safety of Australia’s transport infrastructure, particularly the aviation industry. A new repair technique being developed by Professor Rhys Jones does more than simply patch up the problem; it restores the structural integrity of the metals involved. His research could improve the safety and life span of aircraft globally. It is being tested by the Australian Defence Force and has drawn the attention of international aviation giants Boeing and Airbus.

The Australian Government raised questions about the safety of ageing aviation infrastructure in its 2009 Aviation White Paper. Aviation regulator the Civil Aviation Safety Authority shares these safety concerns.

Rhys’s research is expected to reduce the danger posed by ageing and corroded aircraft.

When exposed to extreme weather and environmental conditions metal develops small defects that grow larger and corrode over time.

‘Metal is like a human body – as it gets older it gets damaged. Just as our DNA does not renew itself properly, the problem of corrosion gets worse over time,’ Rhys says.

His research to address the corrosion issue is an extension of a technique, commonly called ‘cold spray’, that was first developed in Russia in the 1990s to ‘regrow’ aluminium.