CMC Cooling Hole Machining With Dynamic Laser Angle Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser machining methods for forming cooling holes in ceramic matrix composite (CMC) components of gas turbine engines result in tapered holes due to laser beam clipping, leading to suboptimal fluid film effectiveness and heat transfer, and are limited to shallow penetration depths.
Innovation Solution
A laser machining system that orientates the CMC component in multiple positions to adjust the angle of attack of a conically-shaped laser beam, preventing unwanted clipping and allowing deeper penetration without tapering, thereby achieving optimal geometry and improved fluid dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser machining methods are used to form cooling holes in CMC components, then the holes can be created, but the holes become tapered due to laser beam clipping, resulting in poor fluid film effectiveness and suboptimal heat transfer
Solution Approach 1:
The laser system dynamically adjusts the angle of attack of the conically-shaped laser beam relative to the CMC component walls during machining. By changing the beam angle dynamically, the system prevents laser beam clipping on the interior walls, maintaining consistent hole geometry and optimal fluid film effectiveness throughout the cooling hole depth.
Solution Approach 2:
The system changes the angular parameter of the laser beam (angle of attack) during the machining process. This parameter change allows the conically-shaped laser beam to machine through the CMC component without clipping the interior walls, producing straight-walled cooling holes with improved fluid film effectiveness and heat transfer characteristics.
2Length of moving object
If conventional laser machining methods are used, then cooling holes can be formed, but penetration depth is limited to relatively shallow depths as beam clipping and taper increase with depth
Solution Approach 1:
The laser system employs dynamic angle adjustment during the machining process, allowing the conically-shaped laser beam to maintain optimal engagement with the CMC material at varying depths. This dynamic adjustment prevents beam clipping even at greater penetration depths, enabling the formation of deep cooling holes with consistent geometry and straight walls throughout their entire length.
3Length of moving object
If the laser beam angle is increased to achieve deeper penetration, then penetration depth improves, but laser beam clipping on interior walls increases, causing more severe tapering
Solution Approach 1:
Rather than using a fixed high angle, the system dynamically adjusts the laser beam angle during machining. This allows the conically-shaped beam to penetrate deeply into the CMC component while maintaining an optimal angle that prevents interior wall clipping, thereby achieving deep penetration without the severe tapering that would result from a static high-angle approach.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively forms openings with greater depths and improved film effectiveness, reducing material stress and enhancing the operational life of CMC components by preventing laser beam clipping and achieving precise geometry.
Implementation Method 1
A laser system includes a laser source configured to machine the opening with a conically-shaped laser beam
Data Source
AI summary
Systems and methods for machining openings of a component are provided. In one exemplary aspect, a laser system includes features for machining an opening into a component, such as a cooling hole for a CMC component of a gas turbine engine. The component can be oriented in a first position and lasered while oriented in the first position to form a portion of the opening. The component is then oriented to a second position and lasered while oriented in the second position to form another portion of the opening. The component is alternated between the first and second positions until the predetermined geometry of the opening is formed. The component is oriented in the first and second positions such that the laser beam can machine the component without clipping areas that are not desired to be machined.