Systems and methods for detecting laser hole drilling breakthrough

Abstract

To provide systems and methods for detecting a laser hole drilling breakthrough.SOLUTION: A component includes a plurality of cooling holes located on an outer surface of the component, and an air supply system coupled in flow communication to a back surface of each of the plurality of cooling holes. The detection system includes a data acquisition system including at least one sensor and a processor. The processor is configured to cause a laser device to drill a first of the cooling holes, detect an air change in air proximate to the first cooling hole from the air supply system based on data received from the at least one sensor, where the air change is indicative of a drilling breakthrough of the back surface of the first cooling hole, and operate the laser device to stop drilling the first cooling hole based on the detected air change.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates generally to laser drilling breakthrough detection systems and methods, and more particularly to systems and methods used to detect breakthrough of a laser through an exterior surface of a part when drilling cooling holes in the part. [Background technology]

[0002]

[0003] Turbine engines, such as gas turbine engines and steam turbine engines, are widely used in industry and for power generation. During operation, turbine engine components are exposed to high temperatures for extended periods of time. To facilitate cooling of the components and reduce damage caused by extended exposure to high temperatures, at least some known turbine engine components include cooling holes that allow cooling air to circulate through and around at least a portion of the component.

[0003] Typically, cooling holes are drilled into the exterior surface of a turbine engine component using a laser. However, without a proper breakthrough detection method, the laser may drill undesirably too deeply and cause damage to features below the exterior surface of the component. Thus, a need exists for a system and method that can be used to detect laser hole drilling breakthrough of cooling holes on the exterior surface of a component to improve cooling hole drilling efficiency and reduce drilling damage to component features below the exterior surface of the component. Summary of the Invention

[0004] In one aspect, a detection system is provided for use with a component. The component includes a plurality of cooling holes disposed on an exterior surface of the component and an air supply system coupled in flow communication to a backside of each of the plurality of cooling holes. The detection system includes a data acquisition system configured to inspect the plurality of cooling holes, the data acquisition system including at least one sensor and a processor in operative communication with the data acquisition system. The processor is configured to cause a laser device to drill a first of the cooling holes in the exterior surface of the component, the laser device emitting a plurality of laser beam pulses during operation. The processor is also configured to detect an air change in air proximate to the first cooling hole from the air supply system based on data received from the at least one sensor, the air change indicating a drilling breakthrough of the backside of the first cooling hole, and operate the laser device to stop drilling the first cooling hole based on the detected air change.

[0005] In another aspect, a method for detecting laser drilling breakthrough through a backside of at least one cooling hole located on an exterior surface of a component is provided. The method includes operating a laser device to drill at least one cooling hole in the exterior surface of the component, the laser device emitting a number of laser beam pulses during operation. The method also includes detecting, by at least one sensor, an air change in air proximate to the at least one cooling hole from an air supply system based on data received from the at least one sensor, the air change indicative of drilling breakthrough of the backside of the at least one cooling hole, and operating the laser device to stop drilling the at least one cooling hole based on the detected air change. [Brief description of the drawings]

[0006] [Figure 1] 1 is a schematic diagram of a turbine engine component. [Diagram 2] FIG. 2 is a schematic front view of the turbine engine component of FIG. 1. [Diagram 3] 2 is a schematic cross-sectional side view of the turbine engine component of FIG. 1; [Figure 4] FIG. 2 is a schematic diagram of an exemplary detection system for use in analyzing the turbine engine component of FIG. 1. [Figure 5A] 2 is a schematic cross-sectional side view of a laser light beam and the turbine engine component of FIG. 1; [Figure 5B] 2 is a schematic cross-sectional side view of a laser light beam and the turbine engine component of FIG. 1; [Figure 6] 5B is another schematic cross-sectional side view of the turbine engine component of FIG. 5A. [Figure 7] 1 is a flowchart illustrating an exemplary method for analyzing a turbine engine component. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Embodiments described herein relate to systems and methods for use in detecting laser breakthrough through an exterior surface of a part when drilling cooling holes in the part to facilitate improving efficiency of the cooling hole drilling and reducing laser drilling damage to part features below the exterior surface of the part.

[0008] The systems and methods described herein facilitate detection of laser drilling breakthrough through the backside of cooling holes drilled in an exterior surface of a component. Advantages of the systems and methods described herein include at least: (i) improved efficiency of laser drilling of cooling holes by detecting laser drilling breakthrough through the backside of the cooling hole, (ii) improved accuracy and cost-effectiveness of laser drilling breakthrough by measuring air pressure, air flow rate, and / or air temperature within and / or adjacent to the cooling hole, and (iii) improved protection of component features beneath the exterior surface of the turbine engine component adjacent to the cooling hole.

[0009] When introducing elements of various embodiments disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0010] Approximate terms such as "generally," "substantially," and "about" as used herein indicate that, unless otherwise indicated, the term so modified may only be applied to an approximate degree as would be recognized by one of ordinary skill in the art, and not to an absolute or complete degree. Thus, values ​​modified by terms such as "about," "approximately," "substantially," and the like are not limited to the exact value specified. In at least some instances, the approximation may correspond to the precision of an instrument for measuring the value. Furthermore, unless otherwise indicated, terms such as "first," "second," and the like are used herein merely as labels and are not intended to impose any order, position, or hierarchical requirement on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or exclude the presence of, for example, a "first" or lower numbered item, or a "third" or higher numbered item.

[0011] FIG. 1 is a schematic diagram of a turbine engine component 100. The component 100 may be any of a variety of component types used in various turbine engine applications, such as components utilized in high temperature applications. In some embodiments, the component 100 may be a turbine blade, a compressor blade, a vane, a nozzle, a shroud, a rotor, a transition piece, and / or a rotor casing. In other embodiments, the component 100 may be other components of a turbine engine. In an exemplary embodiment, the component 100 includes a plurality of cooling holes 102 formed therein. The cooling holes 102 may facilitate improved air circulation around and / or within the component 100 during operation of the turbine engine. In an exemplary embodiment, the component 100 includes an exterior surface 104 having the cooling holes 102 spaced apart.

[0012] In an exemplary embodiment, the part 100 has a length 106 and a width 108. In the following description, the part 100 may be described as extending "vertically", i.e., along the vertical Y direction, or "horizontally", i.e., along the horizontal XZ plane. It should be understood that these representations are descriptive and should not be construed as overly limiting. In the embodiment of FIG. 1, the length 106 extends vertically along the vertical Y direction, and the width 108 extends horizontally along the horizontal XZ plane. The dimensions of the length 106 and the width 108 may vary, and the part 100 should not be construed as limited to the illustrated shape formed by the length 106 and the width 108 (as shown in FIG. 1).

[0013] 2 and 3 are schematic diagrams of cooling holes 102 formed in a part 100. More specifically, FIG. 2 shows a front view of the part 100, and FIG. 3 shows a cross-sectional side view of the part 100. The cooling holes 102 may have any surface shape and any exit shape that facilitates the systems and methods described herein. For example, the cooling holes 102 may have an elliptical shape on the exterior surface 104 when viewed from the front, as shown in FIG. 2. For all shapes, each cooling hole 102 is defined by a pair of side surfaces 109, a top end 111, and a bottom end 113. As shown in FIG. 2, the side surfaces 109 extend along a surface height 110 of the cooling hole 102, and the surface height 110 is defined between the apex / center of each of the top end 111 and bottom end 113. Further, as shown in FIG. 2, the top end 111 and bottom end 113 each extend along a surface width 112 of the cooling hole 102, with the surface width 112 being defined between the apex / middle of each side 109. The sides 109, top end 111, and bottom end 113 are all combined to form the shape of the cooling hole 102. Although the cooling hole 102 is illustrated as being circular in the figures, this is intended for illustration only and not for limitation. In the exemplary embodiment, as best seen in FIGS. 1 and 2, the surface height 110 is circular, as best seen in FIGS. 1 and 2. The surface height 110 extends vertically along the length 106 (e.g., along a vertical Y direction) and the surface width 112 extends horizontally along the width 108 (e.g., along a horizontal XZ plane).

[0014] 3, each cooling hole 102 extends into the part 100 from the exterior surface 104 to a depth 114 that varies across the surface height 110. In an exemplary embodiment, the cooling holes 102 are shallowest at an upper end 111, where the depth 114 is smallest, and deepest below a lower end 113, where the depth 114 increases across the surface height 110 from the upper end 111 to the lower end 113. In an exemplary embodiment, the depth 114 is deepest at a dip point 116 formed below the lower end 113 (e.g., below the lower end 113 in the vertical Y direction), where the cooling holes 102 are coupled in flow communication with a channel 118 of an air supply system (not shown) of the part 100.

[0015] The air supply system may be any system for supplying air to the cooling holes 102 and / or channels 118 of the part 100, as described herein. For example, the air supply system may be a supply of air from a store supply configured to flow air through the channels 118 of the part 100. Additionally, the air may be cooled prior to proximity to the part 100, such as by a separate chiller, for example.

[0016] 4 is a schematic diagram of an exemplary detection system 200 that may be used to detect backside breakthrough of cooling holes 102 drilled into the exterior surface 104 of the part 100 using a laser. In an exemplary embodiment, the detection system 200 includes a data acquisition system 202 and a control system 204. The control system 204 includes a processor 205 that analyzes data acquired by the data acquisition system 202. In an exemplary embodiment, the cooling holes 102 are drilled into the exterior surface 104 of the part 100 with a laser device 206. The control system 204 uses the data analyzed by the processor 205 to control the operation of the laser device 206 to emit pulses of laser light across the exterior surface 104 of the part 100.

[0017] The data acquisition system 202 may include a pressure sensor 208 that measures air pressure at the opening of the cooling hole 102 proximate the exterior surface 104 of the part 100. The data acquisition system 202 may also include a flow sensor 210 that measures air flow through the cooling hole 102, and / or a temperature sensor 212 that measures a temperature of the exterior surface 104 of the part 100 proximate the cooling hole 102. In this manner, based on the received sensor data, such as from the pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212, the data acquisition system 202 may communicate with the control system 204 and the laser device 206 to facilitate accurate and efficient operation of the laser device 206 in drilling the cooling holes 102 in the exterior surface 104 of the part 100.

[0018] 5A and 5B are schematic diagrams of a cross-sectional side view of a laser device 206 emitting a laser light beam 230 across the exterior surface 104 of the part 100 to enable drilling of the cooling holes 102. In the exemplary embodiment of FIG. 5A, the laser device 206 is controlled by a control system 204 (shown in FIG. 4) such that the laser light beam 230 stops after drilling through the back surface 220 of the cooling holes 102 (e.g., beyond the dip point 116). Without a control system such as, but not limited to, the control system 204 (shown in FIG. 4), the laser device 206 may drill through the back surface 220 of the cooling holes 102 and cause undesirable damage to a part region 232 of the part 100 proximate the dip point 116 of the cooling holes 102, as shown in FIG. 5B.

[0019] The pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212 can collect data used by the control system 204 (shown in FIG. 4) to facilitate control of the operation of the laser device 206. In an exemplary embodiment, air is pushed or pulled through the channels 118 of the cooling air channel system of the part 100, and sensors (such as, but not limited to, the pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212) are used to measure properties of the air flowing through and / or proximate to the part 100. The sensors, including the pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212, can be placed in any location proximate the cooling holes 102 that facilitates data collection for the systems and methods described herein. Thus, the locations of the pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212 in the figures are intended to be illustrative only and not limiting.

[0020] Data collected by the pressure sensor 208, flow sensor 210, and / or temperature sensor 212 may indicate changes in measured properties of the air flowing through and / or proximate to the part 100. In some embodiments, the collected data may be analyzed for statistically significant changes in pressure, flow, and / or temperature. In other embodiments, the collected data may be analyzed for any changes in pressure, flow, and / or temperature, facilitating an increase in the speed of data collection where the measured changes are not required to be statistically significant. For example, changes in pressure, flow, and / or temperature that are not statistically significant but are still collected may be relative to the first derivative of the measured sensor (pressure sensor 208, flow sensor 210, and / or temperature sensor 212), including an analysis of the difference between the measured value and the expected first derivative of the measured sensor.

[0021] The pressure sensor 208 can measure the air pressure through the cooling hole 102. In some embodiments, as shown in FIGS. 5A-5B, the pressure sensor 208 may be located within the cooling hole 102 proximate the entrance of the cooling hole 102 (e.g., proximate the exterior surface 104 of the part 100). In other embodiments, the pressure sensor 208 may be located elsewhere, such as, but not limited to, within the channel 118 proximate the dip point 116 of the cooling hole 102. In an exemplary embodiment, the air pressure measured by the pressure sensor 208 is analyzed by the processor 205 (shown in FIG. 4) to detect when the laser light beam 230 breaks through the back surface 220 of the cooling hole 102 (shown in dashed lines in FIG. 5B). For example, the pressure sensor 208 may measure an increase in air pressure to detect an increase in the amount of air flowing from the channel through the cooling hole 102, such as occurs when the cooling hole 102 is expanded through the back surface 220 by the laser light beam 230. For example, the increase in air pressure may be relative to atmospheric pressure (e.g., the pressure of the air surrounding the part 100) and / or a preset pressure value (e.g., but not limited to, between 14 PSIG and 40 PSIG, between 90 PSIG, and / or between 120 PSIG, etc.).

[0022] The flow sensor 210 can measure the stability of the airflow in the cooling hole 102. In some embodiments, the flow sensor 210 can be located in the cooling hole 102 proximate the dip point 116 of the cooling hole 102, as shown in FIGS. 5A-5B. In other embodiments, the flow sensor 210 can be located elsewhere. In an exemplary embodiment, the stability of the airflow measured by the flow sensor 210 is analyzed by the processor 205 (shown in FIG. 4) to detect when the laser light beam 230 breaks through the back surface 220 of the cooling hole 102 (shown in dashed lines in FIG. 5B). For example, the flow sensor 210 can detect an unstable airflow, such as an increase and / or change in direction of the airflow from the channel 118 through the cooling hole 102, such as occurs when the cooling hole 102 is opened by the laser light beam 230 through the back surface 220.

[0023] The temperature sensor 212 can measure the temperature of the exterior surface 104 of the component 100 proximate the entrance of the cooling hole 102. In some embodiments, as shown in FIGS. 5A-5B, the temperature sensor 212 may be located on the exterior surface 104 proximate the entrance of the cooling hole 102 (e.g., proximate the top end 111 and / or bottom end 113 of the cooling hole 102 on the exterior surface 104). In other embodiments, the temperature sensor 212 may be located elsewhere. In an exemplary embodiment, the temperature measured by the temperature sensor 212 is analyzed by the processor 205 (shown in FIG. 4) to detect when the laser light beam 230 breaks through the back surface 220 of the cooling hole 102 (shown in dashed lines in FIG. 5B).

[0024] For example, the temperature sensor 212 may detect a change in temperature of the exterior surface 104 of the part 100 proximate the entrance of the cooling hole 102 when the laser light beam 230 opens the cooling hole 102 through the backside 220. In such a situation, the temperature of the exterior surface 104 may change as air flows through the cooling hole 102 and into the channel 118 when the cooling hole is opened through the backside 220 by the laser light beam 230. In some embodiments, the temperature sensor 212 may be a thermistor. In other embodiments, the temperature sensor 212 may be a thermocouple. Alternatively, any other temperature detection device that enables the detection system 200 to function as described herein may be used. The change in temperature of the exterior surface 104 of the part 100 may be a change relative to the ambient temperature (e.g., the ambient air temperature proximate the part 100) and / or a change relative to the temperature of the part 100 (e.g., the temperature of the part 100 and not just the exterior surface 104).

[0025] FIG. 6 is another schematic cross-sectional side view of a laser device 206 emitting a laser light beam 230 across the exterior surface 104 of the part 100. As previously described, the laser device 206 emits the laser light beam 230 in pulses to enable drilling of the cooling holes 102. Thus, to enable data collected by the pressure sensor 208, the flow sensor 210, and / or the temperature sensor 212 to be used by the control system 204 (shown in FIG. 4) to control the operation of the laser device 206, the sensor data must be collected at a sensor measurement rate that is faster than the laser light pulse rate of the laser device 206. The laser light pulse rate may also be dependent on the sensor measurement rate. For example, the laser light pulse rate may be decreased to drill at a slower rate than the sensor measurement rate to facilitate improved accuracy of breakthrough detection.

[0026] In an exemplary embodiment, the laser light pulse rate may depend on the drilling depth of the laser light beam 230 as the cooling holes 102 are drilled. For example, as shown in FIG. 6, the depth 114 of the cooling holes 102 may have a first depth 114a extending from the outer surface 104 of the part 100 into the cooling holes 102 and a second depth 114b below the first depth 114a, with the depth 114 being a total depth that is the sum of the first depth 114a and the second depth 114b. The laser light pulse rate may vary between the first depth 114a and the second depth 114b.

[0027] In an exemplary embodiment, the laser light pulse rate in the first depth 114a is higher than the laser light pulse rate in the second depth 114b. That is, the pulse rate of the laser light beam 230 may be faster in the first depth 114a than the pulse rate of the laser light beam 230 in the second depth 114b (e.g., the time td between laser light pulses may be greater in the second depth 114b), facilitating reducing the laser light pulses of the laser device 206 proximate the back surface 220 of the cooling hole 102. The pulse rate of the laser light beam 230 in the second depth 114b may be slower than the sensor measurement rate at which sensor data is collected.

[0028] The first depth 114a and / or the second depth 114b may be determined by the processor 205 (shown in FIG. 4 ) of the control system 204 based on previously drilled cooling holes 102 of the part 100. For example, the processor 205 may calculate an average number of laser light pulses (e.g., a threshold number of pulses) to break through the backside 220 of the cooling holes 102 of the part 100 after a number of cooling holes 102 have been drilled. Based on this threshold number of pulses, the processor 205 may determine that the first depth 114a is within a certain number of pulses of the threshold number of pulses. In some embodiments, the threshold number of pulses may further be based on one or more materials and / or thicknesses of the part measured from the exterior surface 104 of the part 100 to the channels 118 of the air supply system of the part 100.

[0029] The threshold number of pulses may vary across the part 100, where areas of the part 100 may be of different material and / or greater thickness, as measured from the exterior surface 104 of the part 100 to the channels 118 of the air supply system of the part 100, and a greater number of laser light pulses may be required to break through the back surface 220 of the cooling holes 102 in such areas. In other embodiments, the threshold number of pulses may be based on the pulse power of the laser device 206. The pulse power of the laser device 206 may be variably selected by reducing the power of the laser device 206 and / or defocusing the laser light beam 230.

[0030] In some embodiments, the first depth 114a may be determined based on an expected thickness of the part 100. For example, the part 100 may be designed to be a set thickness and the first depth 114a may be up to 95% of the set thickness and / or in a range of 80-95% of the set thickness. In other embodiments, the first depth 114a may be determined based on a statistical analysis of a threshold number of pulses of previously drilled cooling holes 102. For example, the first depth 114a may be up to 95% of the depth drilled by the threshold number of pulses and / or in a range of 08-95% of the depth drilled by the threshold number of pulses.

[0031] 7 is a flow chart illustrating an exemplary method 700 for analyzing a turbine engine component. In an exemplary embodiment, the method 700 includes operating 702 a laser device to drill at least one cooling hole in an exterior surface of the component, the laser device emitting a number of laser beam pulses during operation. The method 700 also includes detecting 704, by the at least one sensor, an air change in air proximate to the at least one cooling hole from an air supply system based on data received from the at least one sensor, the air change being indicative of drilling breakthrough of a back surface of the at least one cooling hole. The method 700 further includes operating 706 the laser device to stop drilling the at least one cooling hole based on the detected air change.

[0032] Described herein are exemplary systems and methods for detecting laser drilling breakthrough through the backside of cooling holes drilled in the exterior surface of a component. The exemplary systems and methods described herein provide several advantages over conventional designs and processes, including improved efficiency of laser drilling of cooling holes by detecting laser drilling breakthrough through the backside of the cooling hole, improved accuracy and cost-effectiveness of laser drilling breakthrough by measuring air pressure, air flow rate, and / or air temperature proximate the cooling hole, and improved protection of component features beneath the exterior surface of the turbine engine component proximate the cooling hole.

[0033] The above description is intended to be illustrative only, and those skilled in the art will recognize that modifications may be made to the described embodiments without departing from the scope of the invention disclosed. Modifications that fall within the scope of the invention will be apparent to those skilled in the art in light of a review of this disclosure, and such modifications are intended to fall within the scope of the appended claims. The systems and methods described herein are not limited to the specific embodiments described herein, but rather, portions of the various systems may be utilized independently and separately from other systems and methods described herein.

[0034] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. Moreover, references to "one embodiment" in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. In accordance with the principles of the invention, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0035] Further aspects of the invention are provided by the subject matter of the following clauses. [Embodiment 1] 1. A detection system for use with a component including a plurality of cooling holes located on an outer surface of the component and an air supply system coupled in flow communication to a back surface of each of the plurality of cooling holes, the detection system comprising: a data acquisition system configured to examine the plurality of cooling holes, the data acquisition system including at least one sensor; and a processor in operative communication with the data acquisition system; Including, The processor, causing a laser device to drill a first of the cooling holes into the outer surface of the component, the laser device emits a number of laser beam pulses during operation; 11. A detection system configured to: detect an air change in air proximate the first cooling hole from the air supply system based on data received from the at least one sensor, where the air change is indicative of a drilling breakthrough of the back surface of the first cooling hole; and operate the laser device to stop drilling the first cooling hole based on the detected air change. [Embodiment 2] 11. The detection system of any of the preceding embodiments, wherein the processor is further configured to perform the steps of: determining a threshold number of laser beam pulses to be emitted by the laser device, the threshold number being the number of laser beam pulses emitted to drill through the back surface of the first cooling hole; and operating the laser device to drill at least one subsequent cooling hole into the outer surface of the component based on the threshold number of laser beam pulses. [Embodiment 3] A detection system as described in any preceding embodiment, wherein the at least one sensor comprises a pressure sensor, and wherein detecting the change in the air comprises detecting an air pressure change within the first cooling hole proximate the outer surface of the component. [Embodiment 4] A detection system as described in any preceding embodiment, wherein the at least one sensor comprises a flow sensor, and wherein detecting the air change comprises detecting an air flow instability within the first cooling hole. [Embodiment 5] A detection system as described in any of the preceding embodiments, wherein the at least one sensor comprises a temperature sensor, and wherein detecting the change in the air comprises detecting a temperature change at the outer surface of the component proximate the first cooling hole. [Embodiment 6] 2. The detection system of any preceding embodiment, wherein the temperature sensor comprises one of a thermistor and a thermocouple. [Embodiment 7] 10. The detection system of claim 1, wherein the temperature change at the outer surface of the component proximate the first cooling hole comprises one of changing relative to an ambient temperature and changing relative to a temperature of the component. [Embodiment 8] 20. The detection system of claim 1, wherein the step of operating the laser device to drill the at least one subsequent cooling hole comprises selectively operating the laser device at a first laser beam pulse rate and at a second laser beam pulse rate, wherein the first laser beam pulse rate is greater than the second laser beam pulse rate. [Embodiment 9] 13. The detection system of any of the preceding embodiments, wherein the laser device is operated at the first laser beam pulse rate for a first number of laser beam pulses and is further operated at the second laser beam pulse rate for a second number of laser beam pulses, and the first number of laser beam pulses and the second number of laser beam pulses are each variably selected based on the determined threshold number. [Embodiment 10] The detection system of any of the preceding embodiments, wherein operating the laser device to drill the at least one subsequent cooling hole comprises operating the laser device based on at least one of a thickness of the component and a material of the component. [Embodiment 11] 20. The detection system of claim 1, wherein the step of operating the laser device to drill the at least one subsequent cooling hole comprises operating the laser device based on a pulse power of the laser device. [Embodiment 12] 1. A method of detecting breakthrough of laser drilling through a back surface of at least one cooling hole located on an outer surface of a component, the component including an air supply system coupled in flow communication to a back surface of the at least one cooling hole, the method comprising: operating a laser device to drill the at least one cooling hole into the outer surface of the component, the laser device emits a number of laser beam pulses during operation; 16. A method comprising: detecting, by at least one sensor, an air change in air proximate the at least one cooling hole from the air supply system based on data received from the at least one sensor, where the air change is indicative of a drilling breakthrough of the back surface of the at least one cooling hole; and operating the laser device to stop drilling the at least one cooling hole based on the detected air change. [Embodiment 13] determining a threshold number of laser beam pulses to be emitted by the laser device, the threshold number is the number of laser beam pulses emitted to drill through the back surface of the at least one cooling hole; 20. The method of any preceding embodiment, further comprising: operating the laser device to drill at least one subsequent cooling hole into the outer surface of the component based on the threshold number of laser beam pulses. [Embodiment 14] The method of any preceding embodiment, wherein detecting by the at least one sensor comprises detecting, by a pressure sensor, an air pressure change within the at least one cooling hole proximate the outer surface of the component. [Embodiment 15] The method of any preceding embodiment, wherein the detecting by the at least one sensor comprises detecting, by a flow sensor, an air flow instability within the at least one cooling hole. [Embodiment 16] The method of any preceding embodiment, wherein the detecting by the at least one sensor comprises detecting by the at least one sensor comprises detecting, by a temperature sensor, a temperature change at the outer surface of the component proximate the at least one cooling hole. [Embodiment 17] 13. The method of any preceding embodiment, wherein detecting by the temperature sensor comprises detecting by one of a thermistor and a thermocouple. [Embodiment 18] The method of any preceding embodiment, wherein the temperature change at the outer surface of the component proximate the at least one cooling hole comprises one of changing relative to an ambient temperature and changing relative to a temperature of the component. [Embodiment 19] 20. The method of any preceding embodiment, wherein operating the laser device to drill the at least one subsequent cooling hole comprises selectively operating the laser device at a first laser beam pulse rate and at a second laser beam pulse rate, wherein the first laser beam pulse rate is greater than the second laser beam pulse rate. [Embodiment 20] 13. The method of any preceding embodiment, wherein the laser device is operated at the first laser beam pulse rate for a first number of laser beam pulses and is further operated at the second laser beam pulse rate for a second number of laser beam pulses, and the first number of laser beam pulses and the second number of laser beam pulses are each variably selected based on the determined threshold number.

[0036] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims. [Explanation of symbols]

[0037] 100: Turbine engine component 102: Cooling hole 106: Length 109: Side 110: Surface height 111: Top 112: Surface width 114: Depth 114a: First depth 116: Dip point 118: Channel 200: Detection system 202: Data acquisition system 204: Control system 205: Processor 206: Laser device 208: Pressure sensor 210: Flow sensor 212: Temperature sensor 220: Back surface 230: Laser light beam 232: Component area

Claims

1. 1. A detection system for use with a component, the component including a plurality of cooling holes disposed on an exterior surface of the component, and an air supply system coupled in flow communication to a rear surface of each of the plurality of cooling holes, the detection system comprising: a data acquisition system configured to inspect a plurality of cooling holes, the data acquisition system including at least one sensor; a processor in operative communication with the data collection system; The processor causing a laser to drill a first cooling hole in an exterior surface of the component, the laser emitting a plurality of laser beam pulses during operation; detecting an air change in air proximate to the first cooling hole from an air supply system based on data received from the at least one sensor, the air change being indicative of a piercing breakthrough of a back surface of the first cooling hole; and activating the laser device to stop drilling the first cooling holes based on the detected change in the air.

2. The processor further comprises: determining a threshold number of laser beam pulses emitted by the laser device, the threshold number being the number of laser beam pulses emitted to drill a back surface of the first cooling hole; and operating the laser device to drill at least one cooling hole in an exterior surface of the component based on a threshold number of laser beam pulses.

3. The detection system of claim 1 , wherein the at least one sensor includes a pressure sensor, and detecting a change in air includes detecting a change in air pressure in a first cooling hole proximate an exterior surface of the component.

4. The detection system of claim 1 , wherein the at least one sensor comprises a flow sensor, and wherein detecting a change in the air comprises detecting an instability in the air flow within the first cooling hole.

5. The detection system of claim 1 , wherein the at least one sensor includes a temperature sensor, and detecting a change in the air includes detecting a change in temperature of an exterior surface of the component proximate the first cooling hole.

6. The detection system of claim 5 , wherein the temperature sensor comprises one of a thermistor and a thermocouple.

7. The detection system of claim 5 , wherein the temperature change at the exterior surface of the component proximate the first cooling hole comprises one of a change relative to an ambient temperature and a change relative to a temperature of the component.

8. 3. The detection system of claim 2, wherein operating the laser device to drill at least one subsequent cooling hole comprises selectively operating the laser device at a first laser beam pulse rate and a second laser beam pulse rate, the first laser beam pulse rate being greater than the second laser beam pulse rate.

9. 9. The detection system of claim 8, wherein the laser device is operated at a first laser beam pulse rate for a first number of laser beam pulses and further operated at a second laser beam pulse rate for a second number of laser beam pulses, the first number of laser beam pulses and the second number of laser beam pulses being each variably selected based on a determined threshold number.

10. 3. The detection system of claim 2, wherein operating the laser to drill the at least one subsequent cooling hole comprises operating the laser based on at least one of a thickness of the part and a material of the part.

11. The detection system of claim 2 , wherein operating the laser to drill the at least one subsequent cooling hole comprises operating the laser based on a laser pulse power.

12. 1. A method for detecting breakthrough of laser drilling through a back surface of at least one cooling hole disposed in an exterior surface of a component, the component including an air supply system coupled in flow communication to the back surface of the at least one cooling hole, the method comprising: operating a laser device to drill at least one cooling hole in an exterior surface of the component, the laser device emitting a plurality of laser beam pulses during operation; detecting, by the at least one sensor, an air change from an air supply system proximate to the at least one cooling hole based on data received from the at least one sensor, the air change being indicative of a perforation breakthrough of a back surface of the at least one cooling hole; and operating the laser device to stop drilling the at least one cooling hole based on the detected change in the air.

13. determining a threshold number of laser beam pulses emitted by the laser device, the threshold number being the number of laser beam pulses emitted to drill a back surface of the at least one cooling hole; and operating the laser to drill at least one cooling hole in the exterior surface of the component based on a threshold number of laser beam pulses.

14. The method of claim 12 , wherein the step of sensing with at least one sensor comprises the step of sensing with a pressure sensor a change in air pressure within at least one cooling hole proximate an exterior surface of the component.

15. The method of claim 12 , wherein detecting with at least one sensor comprises detecting unstable airflow in the at least one cooling hole with a flow sensor.

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