Cooling Hole Re-Establishment After Coating-Induced Deformation

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Solution Overview

Problem

Existing methods for reopening cooling holes in components like divergent flaps or turbine exhaust cases distort the parts and require high accuracy, making it difficult to maintain the original geometry and airflow requirements during coating replacement repairs.

Innovation Solution

A method involving a coordinate measurement machine to map cooling hole locations, generate a macro file, and use a laser drilling apparatus to re-establish holes in the new coating layer, accounting for distortions caused by the coating process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If counterbore style holes are used to reopen cooling holes, then the coating can be applied over the cooling holes, but the hole location accuracy deteriorates due to the larger diameter required to account for distortion

Engineering Contradiction:

Improvecoating applicationVSAvoidhole location accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by mapping and recording the precise locations of cooling holes in the substrate before coating application. This pre-mapping data is stored and later used to guide laser drilling through the coating layer, eliminating the need for larger counterbore holes and maintaining original hole location accuracy despite coating distortion

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical counterbore drilling method with laser drilling guided by pre-mapped coordinates. Instead of using mechanical countersinking to create larger access holes, the system uses digital location data combined with precise laser positioning to drill through the coating at the exact original hole locations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If the component distorts from the coating process, then the coating can be applied to protect the substrate, but the cooling hole locations shift making it difficult to reopen holes with original geometry

Engineering Contradiction:

Improvecoating protectionVSAvoidcooling hole geometry

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The system performs preliminary mapping of cooling hole locations in the substrate before coating application. These pre-recorded coordinates serve as a reference that compensates for coating-induced distortion, allowing the laser drilling system to calculate and adjust hole locations to maintain original geometry despite substrate distortion during coating

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a digital copy or map of the cooling hole locations and substrate geometry before coating. This digital model is used to guide the reopening process, effectively copying the original precise locations and transferring them through the distorted coating layer to achieve accurate hole repositioning

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If high accuracy is required to reopen cooling holes, then the original geometry can be maintained, but the process complexity increases due to the need for precise location mapping and distortion compensation

Engineering Contradiction:

Improvecooling hole geometryVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical measurement and positioning systems with a digital mapping and laser drilling system. Instead of using complex mechanical fixtures and manual measurement tools to maintain precision, the system uses coordinate mapping software and computer-controlled laser positioning, simplifying the overall process while maintaining high accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Precisely re-establishes cooling holes with accurate geometry, maintaining airflow and signature similar to the original equipment manufactured (OEM) specifications, while avoiding damage to existing holes.

Implementation Method 1

drilling the new coating layer using a laser at the at least one mapped location as modified

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentEP4650567A1Methods for re-establishing cooling holes in components having deformation

Publication Date: 2025.11.19 RTX CORP

Figure 1A~1B
Figure 1C~1D
Figure 2

AI summary

A system (300) includes a laser drilling apparatus (302) having a laser (304) to drill into coating layers of a component (100). The component (100) includes cooling holes (106A, 106B) through a substrate (104) and an existing layer (102). The existing coating layer (102) is stripped from the component (100). The locations of the cooling holes (106A, 106B) are mapped using a coordinate measurement machine that generates a macro file (240) of the locations. The macro file (240) is loaded onto the laser drilling apparatus (302). A new coating layer (150) is applied that covers the cooling holes (106A, 106B). The laser drilling apparatus (302) collects data at the locations mapped to the macro file (240) of the component (100) having a new coating layer (150). A modification is made to the locations of the at least one cooling holes (106A, 106B) based on a parameter in the collected data. The laser drilling apparatus (302) drills using the laser (304) at the modified locations into the new coating layer (150).