Scientists and engineers at the Manufacturing Technology Centre (MTC) in Coventry have been working with one of the country’s leading surface-engineering and metal-coating companies to develop an “ultra-resilient alloy”, using the latest shot-peening techniques.

Towcester-based Sandwell UK Ltd (www.sandwell-uk.com) carries out surface-coating and shot-peening processes for a number of high-stress applications — including aerospace and Formula One — that produce stress layers designed to strengthen the mechanical properties of metal parts.

In the latest programme being carried out by the MTC (www.the-mtc.org) and Sandwell UK (part-funded by the Government’s REACH fund for SMEs and delivered by the MTC), engineers have developed a process that results in a highly resilient nano-structured surface on nickel alloy.

After the process, the alloy has hardness properties suitable for the most high-fatigue environments found in spacecraft, satellites, aerospace and Formula One applications.

The process can also be used in renewable-energy systems, such as highly loaded wind-power components.

The research is continuing, with funding from Innovate UK; and while these results have previously been achievable in a laboratory, MTC and Sandwell UK engineers have developed the process for commercial volume production.

A further result of the process is that the treated metal has anti-bacterial properties, which could make it suitable for medical applications and implant parts.

Colin McGrory, technical director of Sandwell UK, said: “The surface structure resulting from the new process can significantly improve the fatigue performance of the material, while also reducing the effects of chemicals and the rate of bacterial growth on the surface.

“We will continue to assess the benefits in material performance.”