Laser Ablation Path Planning for Gas Turbine Cooling Holes
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Solution Overview
Problem
The existing methods for clearing debris and obstructions from numerous holes in gas turbine parts after coating are inefficient, requiring substantial time and effort, and often result in physical movement that increases process inefficiency and potential damage to the parts.
Innovation Solution
A method and apparatus utilizing a laser ablation system that establishes specific ablation characteristics for different working zones, creating a laser path plan to efficiently clear holes without physical translation of the laser or the part, minimizing thermal damage and optimizing laser operating parameters such as pulse width and power to maximize debris removal while protecting the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If computer-controlled cutting devices are used to clear debris from numerous holes on complex contoured surfaces, then hole clearing can be performed, but the process becomes difficult and time consuming due to required movement and reorientation of the laser for each hole
Solution Approach 1:
Instead of moving the laser to each hole, the patent inverts the approach by moving the workpiece (article) through the stationary laser beam. The article is conveyed on a conveyor system that passes it through the laser's path, allowing the laser to clear all holes without physical repositioning. This inversion of motion resolves the contradiction by eliminating time-consuming laser reorientation while maintaining effective hole clearing.
Solution Approach 2:
The patent replaces the mechanical system of moving and reorienting the laser with an automated conveyor system that moves the workpiece. This substitution eliminates the need for complex laser positioning mechanisms and manual intervention, significantly reducing process time while maintaining ease of manufacture through automated control.
2Ease of operation
If physical movement of cutting devices or part is performed in preparation for next process step, then hole clearing can be accomplished, but overall process efficiency decreases and potential damage to parts increases
Solution Approach 1:
The patent inverts the traditional approach by keeping the laser stationary and moving the article through it via conveyor system. This eliminates physical handling and repositioning of the part, thereby maintaining part integrity and reliability while still achieving effective hole clearing operation.
Solution Approach 2:
The conveyor system automatically moves the article through the laser beam without requiring manual intervention or additional positioning steps. The system serves itself by integrating the motion function into the conveyor, eliminating separate handling operations that could compromise part integrity.
3Manufacturing precision
If laser is moved and reoriented for each hole on complex surfaces, then complete hole clearing is achieved, but device complexity and operation difficulty increase
Solution Approach 1:
Instead of complex laser positioning systems that move and reorient for each hole, the patent inverts the approach by using a simple stationary laser and moving the article on a conveyor. This dramatically reduces device complexity while maintaining manufacturing precision through consistent laser positioning and controlled article motion.
Solution Approach 2:
The stationary laser system serves multiple holes across the entire article surface without requiring repositioning. The conveyor system provides universal motion capability, transporting various articles through the laser path. This multi-functionality reduces device complexity while maintaining complete hole clearing capability.
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 significantly reduces the time and effort required to clear holes, enhances process efficiency, and minimizes thermal damage to the gas turbine parts, allowing for faster and more effective debris removal without negatively impacting the parts or coatings.
Implementation Method 1
Ablating the first working zone with a first ablation characteristic and afterwards ablating the second working zone with a second ablation characteristic
Data Source
AI summary
A method of laser ablation of one or more holes in an article includes a step of establishing an ablation characteristic. The ablation characteristic is a laser characteristic, a working zone characteristic, a cooling hole characteristic, or a synchronized machine motion characteristic. A creating step creates a laser path plan for a laser beam based on the established ablation characteristic for a first working zone and a second working zone of the article. An ablating step ablates the first working zone with a first ablation characteristic and afterwards ablates the second working zone with a second ablation characteristic which is different from the first ablation characteristic.