scholarly journals Advances in Laser Drilling of Turbine Engine Components

1995 ◽  
Author(s):  
Terry L. VanderWert
Keyword(s):  
Process Control ◽  
Laser Processing ◽  
High Speed ◽  
Laser Drilling ◽  
Drilling Process ◽  
Automatic Production ◽  
Turbine Engine ◽  
Laser Systems ◽  
Engine Components ◽  
Improved Methods

The application of laser systems for drilling turbine engine components has continued to grow. New designs for components are being made as understanding of the process has increased and as capability of laser systems has grown. Advances in process control have led to higher throughput and quality in automatic production. Greater understanding of the laser drilling process has led to improved methods for controlling the spatter and remelt that are characteristic of laser processing. Availability of high speed. PC based controls has facilitated high speed sensing of the component location for precise and repeatable positioning of laser drilled features. This paper describes recent advances in laser drilling turbine engine components. Current capabilities of laser drilling are summarized.

Cu-Direct Laser Drilling of Blind Via-Hole in Multi-Layer PWBs: Process Visualization Using High-Speed Camera Images

2012 ◽  
Vol 516 ◽  
pp. 30-35 ◽  
Author(s):  
Kuniyoshi Obata ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa
Keyword(s):  
High Speed ◽  
Substrate Surface ◽  
Laser Drilling ◽  
Drilling Process ◽  
Positional Accuracy ◽  
Board Density ◽  
Process Visualization ◽  
Direct Laser ◽  
Via Holes ◽  
Direct Drilling

Electrical circuits of Printed Wiring Boards (PWBs) have become multi-layered. Therefore, the formation of micro-blind holes for interlayer electrical connections (blind via holes: BVH) is required. As a result, Cu-direct laser drilling is attracting attention. However, Cu-direct drilling is problematic in that it produces a copper overhang as a result of copper and resin, which have different decomposition points, being melted simultaneously. In addition, the state of PWB surface after the laser drilling is very important. However, this procedure restricts the board density that can be achieved as a result of the limited positional accuracy of the etching process. Consequently, using a Cu-direct drilling process, which does not require etching of the copper foil, to drill BVHs to connect copper foils using a CO2 laser beam has been receiving considerable attention for the next-generation high density PWB manufacturing. However, in the Cu process of generating a direct and overhang problem, there is the problem of accuracy on the substrate surface. In contrast, in-depth research on quality companies has not been performed. Thus, we observe the removal process. Furthermore, we demonstrated reduced overhang.

scholarly journals Characterisation of Laser System Power Draws in Materials Processing

2020 ◽  
Vol 4 (2) ◽  
pp. 48
Author(s):  
Nicholas Goffin ◽  
Lewis C. R. Jones ◽  
John Tyrer ◽  
Jinglei Ouyang ◽  
Paul Mativenga ◽  
...  
Keyword(s):  
Laser Processing ◽  
High Speed ◽  
Manufacturing Industry ◽  
Laser System ◽  
Processing System ◽  
Fibre Laser ◽  
Beam Power ◽  
Total System ◽  
Laser Systems ◽  
System Power

Due to their high speed and versatility, laser processing systems are now commonplace in many industrial production lines. However, as the need to reduce the environmental impact from the manufacturing industry becomes more urgent, there is the opportunity to evaluate laser processing systems to identify opportunities to improve energy efficiencies and thus reduce their carbon footprint. While other researchers have studied laser processing, the majority of previous work on laser systems has focused on the beam–material interaction, overlooking the whole system viewpoint and the significance of support equipment. In this work, a methodical approach is taken to design a set of energy modelling terminologies and develop a structured power metering system for laser systems. A 300 W fibre laser welding system is used to demonstrate the application of the power characterization system by utilizing a purpose-built power meter. The laser is broken down according to sub-system, with each part analysed separately to give a complete overall power analysis, including all auxiliary units. The results show that the greatest opportunities for efficiency improvements lie in the auxiliary units that support the laser devices as these were responsible for a majority of the electrical draw; 63.1% when the laser was operated at 240 W, and increasing as the beam power reduced. The remaining power draw was largely apportioned to electrical supply inefficiencies. In this work, the laser device delivered a maximum of 6% of the total system power. The implications of these results on laser processing system design are then discussed as is the suitability of the characterization process for use by industry on a range of specific laser processing systems.

scholarly journals Laser Drilling Effusion Cooling Holes in Low NOx Turbine Engine Components

1996 ◽  
Author(s):  
Terry L. VanderWert ◽  
Scott A. Litzer ◽  
Loh Wai Meng
Keyword(s):  
Fuel Efficiency ◽  
Laser System ◽  
Major Change ◽  
Laser Drilling ◽  
Drilling Process ◽  
Combustion Chambers ◽  
Turbine Engine ◽  
Minimum Number ◽  
Key Aspects ◽  
Cooling Air

The move to turbine engine designs featuring low NOx emissions and greater fuel efficiency has resulted in a major change in design and manufacture of certain engine parts such as combustion chambers. For example, effusion cooling combustor designs use thousands of 0.5 mm diameter, shallow angle (less than 30 degrees from the surface) holes to provide a film of cooling air over the surface of the combustor. A variety of thermal barrier coatings are also used to protect the surface during operation. Laser drilling is playing a key role in the production of effusion cooling holes. Laser drilling, which uses the focused output of a high power industrial pulsed Nd:YAG laser to trepan the holes, has become the process of choice for producing these because of: - low heat input - rapid drilling rates - ability to drill ceramic coated metals - a minimum number of process variables contributes to reliable, repeatable processes This paper reviews the laser drilling process for producing effusion cooling holes, characteristics of the holes, and developments aimed at increasing the throughput and, therefore, reducing the cost for laser drilling. The paper also summarizes the key aspects of the laser system required to produce combustors that meet airflow and other quality (metallurgical) specifications.

scholarly journals Microstructure and microhardness of nickel-base heat-resistant alloys obtained by directional and equilibrium crystallization

2019 ◽  
Vol 5 (3-4) ◽  
pp. 33-38
Author(s):  
Andriy Trostianchyn ◽  
◽  
Serhii Shvachko ◽  
Volodymyr Kulyk ◽  
Eduard Pleshakov ◽  
...  
Keyword(s):  
Gas Turbine ◽  
High Speed ◽  
X Ray Diffraction ◽  
Turbine Engine ◽  
X Ray ◽  
Heat Resistant ◽  
Operational Life ◽  
Significant Difference ◽  
Nickel Base ◽  
Engine Components

In order to determine the safe operational life of the components of gas turbine engines (GTE), introductory tests of nickel-base heat-resistant alloys (NHRA) have been performed. X-ray fluorescence and X-ray diffraction analyzes, optical microscopy and Vickers hardness measurements provided data on the phase-structural state and mechanical properties of the pristine ZhS6K-VI and ZhS32-VI alloys obtained by equilibrium and high-speed directional crystallization, respectively. Almost complete compliance of the investigated materials with the certified alloys in chemical and phase composition has been found. A significant difference in the parameters of the fragments of the microstructure of the investigated alloys, which is naturally consistent with the conditions of equilibrium and high-speed directional crystallizations, was revealed. A slightly lower anisotropy of microhardness (2.8 %), measured in transverse and longitudinal sections, was found in the ZhS6K-VI alloy as compared to the anisotropy (5.1 %) in the ZhS32-VI alloy. The obtained results will be used to test a non-destructive method for determining the safe operational life of gas turbine engine components.

Modelling of heat transfer in waterjet guided laser drilling of silicon

2003 ◽  
Vol 217 (5) ◽  
pp. 583-600 ◽  
Author(s):  
C-F Li ◽  
D B Johnson ◽  
R Kovacevic
Keyword(s):  
Laser Beam ◽  
Silicon Substrate ◽  
Laser Processing ◽  
High Speed ◽  
Simulation Method ◽  
Laser Drilling ◽  
Phase Changes ◽  
Workpiece Material ◽  
Model And Simulation ◽  
High Degree

Waterjet guided laser processing is an internationally patented technique based on guiding a laser beam inside a thin, high-speed waterjet. The process combines the advantages of laser processing with those of waterjet cutting. It is very suitable in processing thin and heat-sensitive materials with a high degree of precision required. A model and simulation method for waterjet guided laser drilling on a silicon substrate are presented in this study. A finite difference method has been developed to simulate the thermal field and phase changes involved. The model represents the thermal process in detail. The simulation results predict the main characteristics of waterjet guided laser drilling. The study gives insight into the interactions between the laser beam, waterjet and workpiece material during drilling of a silicon substrate.

Development of Advanced Diagnostics for Turbine Disks

1990 ◽  
Author(s):  
J. R. Dunphy ◽  
W. H. Atkinson
Keyword(s):  
High Speed ◽  
Strain Sensors ◽  
Strain Gages ◽  
Thin Metallic Film ◽  
Turbine Engine ◽  
Static Strain ◽  
Thermographic Phosphor ◽  
Turbine Disks ◽  
Reference Measurements ◽  
Engine Components

Quantitative diagnostics are essential for use during design optimization studies of turbine engine components to insure that performance goals and lifetime requirements are met. This paper addresses development and testing of sensors for diagnostic application in turbine hot sections. Technologies tested during this investigation included optical fiber static strain sensors, thin metallic film static strain sensors, advanced wire static strain sensors, thermographic phosphor temperature sensors and heat flux sensors. Reference measurements for the strain sensors were provided by speckle photogrammetry and conventional strain gages, while reference measurements for temperature sensor were provided by optical pyrometry and conventional thermocouples. Simulated engine conditions typical of a high pressure turbine disk were provided by operating a disk in a high speed spin–rig which ran to 13200 revolutions per minute and 950 K. Representative results and application issues will be provided for each sensor type.

Applications of Laser Systems to Cutting, Drilling and Welding Turbine Engine Parts

1994 ◽  
Author(s):  
Terry L. VanderWert
Keyword(s):  
Laser Processing ◽  
Laser Cutting ◽  
Laser Energy ◽  
Just In Time ◽  
Laser Materials ◽  
Turbine Engine ◽  
Design Changes ◽  
Engine Part ◽  
Laser Systems ◽  
And Control

Multi-axis laser materials processing systems are having a significant impact on the way turbine engine parts are being cut, drilled, and welded. The success of laser cutting, drilling and welding is based in the ability to concentrate laser energy into a small area and to produce features having narrow heat affected zones. Reduced tooling expense, fast turnaround, and flexibility for handling design changes and for economical small lot manufacturing are some of the benefits associated with laser processing of turbine engine parts. For example, in replacing hand trimming, laser cutting has increased throughput for trimming a deep drawn gas turbine engine part from 18 pieces per day to 18 pieces in 30 minutes. For another company, laser cutting saved $75,000 in tooling expense for an application involving drilling of 3500, 0.33 mm diameter holes in a 0.36 mm thick turbine engine blade insert. Laser cutting and welding have been key to a major aircraft manufacturer’s implementation of Just-In-Time manufacturing practices. Recent advances in design and control of laser processing systems have increased the number of applications for laser processing turbine engine parts. New processes have increased the range of applications for which laser processing is qualified. In-process gaging has been used to automate processes that were previously manual and, in doing so, increase the quality of the finished part and productivity of the manufacturing operation. This paper reviews the laser processes used to cut, drill, and weld turbine engine parts. Some typical applications are presented to illustrate the benefits of laser systems for processing turbine engine parts.

Sign in / Sign up

Export Citation Format

Share Document