Active Materials & Manufacturing Chemistry

Addressing the next generation of EHLA manufacturing challenges

In plain English

AI plain-English summary

A new laser-based metal deposition process called Extreme High-speed Laser Application (EHLA) is moving from the lab into UK factories, and this renewal grant aims to solve the manufacturing challenges that come with scaling it up. EHLA works by spraying metal powder into a high-speed laser beam, fusing it onto a surface much faster and with less waste than conventional techniques. The original Fellowship proved the process works for coating and repairing rotationally symmetric parts—like turbine shafts or hydraulic rods—and companies are now industrialising it. But applying EHLA to complex, freeform shapes—such as custom repair patches or intricate add-on features—remains unreliable. The research also lacks the digital tools and quality assurance methods needed for consistent, certified production. If successful, this work could make EHLA a standard tool for repairing high-value engineering components—saving energy, material, and cost compared to replacing them. It could also enable new additive manufacturing designs that are currently impossible with slower deposition methods. The project will build the UK’s first dedicated EHLA research facility at The Welding Institute, creating a reference hub of expertise for industry. The four research pillars—technology uptake, freeform industrialisation, novel ideas, and digital quality assurance—are all aimed at turning a promising prototype process into a reliable manufacturing workhorse.

View original technical description
Extreme High-speed Laser Application (EHLA) is a novel metallic deposition process that can be used effectively for the applications of coatings, repair, and additive manufacturing. This new process has been proven through Josh Barras's FLF to be game-changing within its field and amongst competitive state-of-the-art technologies. EHLA has now started to be industrialised by UK and worldwide companies, for rotationally symmetric coating and reconditioning applications. The processes potential benefits have also been validated as a disruptive technology for freeform deposition in areas of complex coatings, repair, and additive manufacturing . The aims of the research aligns to the Fellows mission statement; With Global Recognition, establish a reference capability of researchers, expertise, and infrastructure with a credible and thorough understand of the EHLA technology and its principal behaviours and potential applications. With this, the Fellowship renewal will build on the roots built in the original programme, presenting four new pillars of research: Championing EHLA technology take-up (1) Industrialising freeform EHLA (2) Investigating novel ideas (3) Fostering digital tools and quality assurance (4) The research will be undertaken by Fellow Josh Barras and hosted within The Welding Institute. The UK's first and leading facility dedicated the high-speed laser deposition process of EHLA will use state-of-the-art process equipment to conduct practical research of materials, process, applications, and system technology.

View the original record at the funder ↗

Researchers

Josh Barras (Principal Investigator)

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Original classification

Fellowship

Plain English summaries and category classifications on this site are generated by AI and may not perfectly reflect the original research.