Cooling Hole Laser Cleaning Without Aerofoil Damage
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Solution Overview
Problem
Debris accumulation in cooling holes of gas turbine engine components reduces cooling efficiency, leading to potential component failure and increased maintenance costs, as existing methods for debris removal can damage the components or require engine disassembly.
Innovation Solution
A method involving a beam of energy coaxially aligned with the aperture, with a diameter less than the aperture, is used to remove debris from cooling holes without damaging the surrounding substrate or coating, allowing for in-situ debris removal without disassembling the engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional debris removal methods are used, then debris can be removed from cooling holes, but the aerofoil and surrounding coating may be damaged
Solution Approach 1:
The patent replaces traditional mechanical debris removal tools (such as drills, reamers, or mechanical cleaners) with a laser beam. The laser energy selectively vaporizes or melts debris material without requiring physical contact with the aerofoil structure, thereby eliminating mechanical stresses and forces that could damage the coating or substrate. This substitution of mechanical action with optical/thermal energy resolves the contradiction between effective debris removal and preservation of component integrity.
Solution Approach 2:
The patent utilizes controlled changes in laser beam parameters (energy density, pulse duration, wavelength, focal point) to selectively remove debris while preserving the surrounding material. By adjusting these parameters, the laser can be tuned to affect only the debris material properties without reaching or damaging the coating or substrate, thus resolving the contradiction between removal effectiveness and structural preservation.
2Reliability
If component disassembly is required for debris removal, then debris can be accessed and removed, but operational service life is reduced and service costs increase
Solution Approach 1:
The laser debris removal system is designed to be applied directly to the engine component in its installed position, allowing the component to serve itself without requiring removal from the engine. The laser can be positioned to access cooling holes through the component's external surfaces, enabling debris removal while the component remains in situ, thus eliminating downtime and associated costs.
Solution Approach 2:
The patent enables debris removal to be performed as a routine maintenance task before it critically impacts cooling efficiency. By allowing easy, non-invasive access to cooling holes through the laser method, debris can be removed proactively during scheduled maintenance windows without requiring engine disassembly, thereby preserving operational service life and reducing unexpected downtime.
3Productivity
If cooling efficiency is reduced due to debris accumulation, then component temperature increases, but this accelerates degradation and may lead to component failure
Solution Approach 1:
The laser debris removal system enables continuous or periodic restoration of cooling hole functionality, maintaining uninterrupted cooling efficiency. By allowing frequent, easy debris removal without component disassembly, the system ensures that cooling passages remain clear and functional throughout the component's operational life, preventing temperature-related degradation and extending reliability.
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
Effectively removes debris from cooling holes, maintaining component integrity and reducing service life and cost impacts by enabling in-situ cleaning, thus enhancing the operational efficiency and longevity of gas turbine engines.
Implementation Method 1
exposing the debris to the beam of energy in order to remove the debris from the aperture
Data Source
AI summary
A method for the removal of debris (75) from an aperture (60), the aperture comprising a first aperture diameter (64) and extending along a first axis (62) over a first distance (63), the method comprising the steps of aligning a beam of energy (80) with the first axis such that the beam of energy is coaxially aligned with the aperture, the beam of energy comprising both an energy sufficient to remove the debris, and a first beam diameter (82) which is less than the first aperture diameter; and, exposing the debris to the beam of energy in order to remove the debris from the aperture.