UMass and MIT demonstrate Cold Spray bridge repair
A team led by the University of Massachusetts Amherst, in collaboration with researchers from the Massachusetts Institute of Technology (MIT) Department of Mechanical Engineering (MechE), has demonstrated in an in-field case study in western Massachusetts that Additive Manufacturing may provide a cost-effective, minimally disruptive solution to bridge deterioration. With more than half of US bridges experiencing deterioration, the approach could significantly reduce maintenance costs and extend service life if scaled. The work highlights growing momentum for field-deployable AM to support critical infrastructure sustainment and resilience.
A proof-of-concept repair was conducted on a small, corroded section of a bridge in Great Barrington, Massachusetts. Cold Spray Additive Manufacturing can extend the life of beams by reinforcing them with newly deposited steel. The process accelerates steel powder particles in heated, compressed gas. A technician then applies the steel onto the beam using a spray applicator. Repeated sprays create multiple layers, restoring thickness and other structural properties.
This method has proven to be an effective solution for other large structures, such as submarines, airplanes, and ships, but bridges present additional logistical challenges due to their size and fixed location. Repairs must also be made with minimal disruptions to traffic, which the team reports can be achieved using this approach.
“Now that we’ve completed this proof-of-concept repair, we see a clear path to a solution that is much faster, less costly, easier, and less invasive,” said Simos Gerasimidis, associate professor of civil and environmental engineering at UMass Amherst and former visiting professor in the Department of Civil and Environmental Engineering at MIT. “To our knowledge, this is a first. Of course, there is some R&D that needs to be developed, but this is a huge milestone to that.”
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John Hart, Class of 1922 Professor and head of the Department of MechE at MIT, and Haden Quinlan, senior program manager in the Center for Advanced Production Technologies at MIT, are leading MIT’s efforts in the project. Hart shared, “This is a tremendous collaboration where cutting-edge technology is brought to address a critical need for infrastructure in the commonwealth and across the United States.”
Quinlan commented, “Integrating digital systems with advanced physical processing is the future of infrastructure. We’re excited to have moved this technology beyond the lab and into the field, and grateful to our collaborators in making this work possible.”
The bridge in Great Barrington is scheduled for demolition in a few years. Following demolition, the repaired beams will be returned to UMass for testing to evaluate adhesion, corrosion behaviour and mechanical properties compared to laboratory-controlled repairs.
