Laser Drill Hole Completion Control for Turbine Airfoils
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Solution Overview
Problem
Current methods for laser drilling of cooling passages in turbine airfoils often result in incomplete holes due to premature cessation of the laser drill upon breakthrough, leading to reduced fluid flow and increased maintenance costs.
Innovation Solution
A method involving the use of a laser drill to create holes in airfoils, where the breakthrough is detected and the drill continues operation based on calculated time durations between breakthroughs, ensuring complete hole formation without damaging the airfoil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser drill continues operation after breakthrough, then the hole becomes complete with improved fluid flow, but the airfoil may be damaged
Solution Approach 1:
The system uses sensors to detect breakthrough events and provides feedback to the controller, which then adjusts the laser drill operation accordingly. This closed-loop control enables the system to continue drilling after breakthrough to complete the hole while monitoring for damage conditions, resolving the contradiction between hole completion and airfoil damage prevention.
Solution Approach 2:
The laser drill operation is made dynamic by allowing it to continue after breakthrough rather than stopping immediately. The system dynamically adjusts drilling parameters and timing based on real-time conditions, enabling complete hole formation while preventing damage through controlled dynamic operation.
2Object-affected harmful factors
If the laser drill stops immediately upon breakthrough, then the airfoil is protected from damage, but the hole remains incomplete reducing fluid flow
Solution Approach 1:
The feedback mechanism allows the system to detect breakthrough and make an informed decision about continued operation. By monitoring breakthrough events and using this information to control drilling duration, the system achieves both airfoil protection and complete hole formation for optimal cooling passage effectiveness.
Solution Approach 2:
The system changes operational parameters (drilling duration, laser power, pulse frequency) based on breakthrough detection. By adjusting these parameters dynamically, the system prevents airfoil damage while ensuring complete hole formation, thereby maintaining both protection and productivity.
3Measurement precision
If multiple sensors are used to detect breakthrough, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The detection system is segmented into multiple sensors positioned at different locations (inside and outside the airfoil). Each sensor monitors specific aspects of the breakthrough event, and their combined information provides accurate detection without requiring a single complex sensor 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
This approach allows for the completion of holes in airfoils, enhancing fluid flow and reducing maintenance needs by accurately determining the completion of drilling through precise timing and patterned drilling techniques.
Implementation Method 1
A laser drill may also be used to create the cooling passages through the airfoil
Implementation Method 2
determining that the laser drill has broken through the near wall of the airfoil
Data Source
AI summary
The present disclosure provides a method for determining a hole completing in laser drilling of a hole in a near wall of an airfoil. The method includes drilling a hole in the near wall of the airfoil using a laser drill. The laser drill may move in a pattern relative to the airfoil. The method also includes determining when the drilling of the hole is complete based on a calculated time duration between successive breakthroughs of a laser from the laser drill through the near wall of the airfoil, or based on a calculated time duration since the latest breakthrough of the laser from the laser drill through the near wall of the airfoil.