Localized Electrochemical Repair (LER) of Conductive Materials

Circular economy models emphasize material repair, akin to nature's healing processes. However, while polymer healing has garnered attention, repairing metals and metal matrix composites (MMCs) remains less extensively studied. Herein, “localized electrochemical repair (LER)”, a process adept at efficiently mending conductive materials, is introduced. LER involves a nozzle with electrolyte near damage, creating a small electrochemical cell that guides controlled metal ion deposition. Notably, LER's energy efficiency, as low as 40 J mm⁻¹, significantly outperforms other methods. This energy efficiency is one-fifth of that required for conventional bath-based electrohealing methods. Through the successful repair of a copper/alumina MMC that achieves ≈100% strength recovery, the effectiveness of LER is demonstrated and interface properties are assessed. LER aligns with circular economy ideals, offering precise, localized healing that is eco-friendly and economically sound. It restores conductive materials while minimizing energy use and waste.