Your Partner in Precision Repairs

Trusted experts in high-value, precision aerospace and critical components part repairs for over 30 years.

THE PROCESS

We combine advanced inspection methods with specialized machining and coating techniques to restore components to — and often beyond — their original performance.

01

Deep Clean

All components undergo a vapor degreasing process to remove contaminants and prepare the surface for inspection.

02

Initial Inspection

We perform a Dye Penetrant Inspection (DPI) to detect surface cracks, flaws, or defects, even on complex shapes and both magnetic & non-magnetic materials.

03

Detailed Assessment

Using advanced testing methods, we analyze the part’s integrity:

Pressure Testing for sealing capability
Electronic Gages for precision measurements
Optical Instruments for micro-level inspection
Grit or Glass Bead Cleaning to expose hidden issues

04

Issue Recording & Pre-Repair Preparation

If defects are found, we document all findings and determine the optimal repair approach:

Pre-machining damaged sections
Removing compromised material
Conducting metal alloy analysis to confirm material composition
Preparing for welding, thermal spray, or custom processes

05

Welding & Thermal Spray Repairs

We restore worn surfaces and damaged areas using advanced deposition techniques:

Welding Repairs for structural integrity
Arc Spray or Plasma Spray Coatings for rebuilding precision fits
Material Optimization:
- Ceramic Coatings → Increased hardness & wear resistance
- Bronze Coatings → Enhanced lubricity & smoother operation

Thermal spraying maintains component integrity with temperatures kept below 200°F

06

Final Machining & Precision Sizing

After welding and thermal spray:

Components are machined or ground back to exact OEM tolerances
NIST-certified measurement tools guarantee sizing accuracy
Ensures precise fits for bearings, seals, and mating surfaces

Precision You Can Trust

For over 30 years, Metal Fusions Inc. (MFI) has been a trusted partner in the aerospace industry, developing over 100 FAA-approved DER repairs for high-value and often impossible-to-replace components. We’ve helped aerospace companies keep critical systems in the air by restoring components to OEM — and often better-than-original — specifications.

With our FAA approvals, NIST-certified measurements, and expertise in advanced welding, thermal spray, and precision machining, we ensure every repair meets the highest industry standards.

Our Expertise

MFI combines cutting-edge repair techniques with strict quality standards to deliver reliable, precision-driven results.

FAA-Approved Facility for aerospace inspections and repairs
TIG Welding and Thermal Spray Processes
Large-Scale Conventional Machining for high-value components
Precision Grinding & Lapping achieving two light bands flatness
Dye Penetrant Inspections per NAS 410 and ASTM 1417
Versatile Component Handling — from 1 mm micro-components up to 16 ft long and 40" in diameter

Why Industry Leaders Choose Us

40+ Years perfecting seal face grinding & lapping
Small-Batch, High-Value Specialists — we focus on quality, not mass production
Expertise in restoring hard-to-replace and high-precision aerospace parts
Proven Track Record of FAA-approved DER repairs for mission-critical components
Certified Quality Standards:
- FAA-Approved Facility for inspections and repairs
- Dye Penetrant Inspections per NAS 410 and ASTM 1417
- NIST-Certified Measuring Tools for precision tolerances

Repair Quote

Our Commitment to Quality

At Metal Fusions Inc. (MFI), every repair goes through rigorous inspection, precision machining, and FAA-approved testing to ensure absolute reliability. Whether it’s a one-off component or a mission-critical aerospace part, our small-batch, high-value focus guarantees uncompromising quality on every project.

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