Vacuum Degassing Laser-Blocking Material for Turbine Drilling
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Solution Overview
Problem
Laser drilling of holes in gas turbine engine components, such as film-cooling holes, often results in minor damage to internal surfaces due to the laser beam penetrating through to the opposite side, leading to scrapped components, as existing methods fail to effectively block the laser beam from reaching the opposite side of internal passageways.
Innovation Solution
A method and system for injecting a molten laser-blocking material into the workpiece, creating an enclosed environment with a partial vacuum to expand and remove air bubbles from the material, ensuring it is air bubble-free before hardening and allowing laser drilling, using materials like epoxy resin or wax to prevent laser penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser drilling is performed on gas turbine engine components, then film-cooling holes are effectively created, but the laser beam penetrates through to the opposite side causing damage to internal surfaces
Solution Approach 1:
The patent applies preliminary action by injecting laser-blocking material into the internal passageways before laser drilling occurs. This pre-positioned material creates a protective barrier that prevents laser beam penetration damage to internal surfaces while allowing the drilling process to proceed effectively.
Solution Approach 2:
The patent uses an intermediary substance (laser-blocking material such as epoxy resin or wax) that is injected into the internal passageways. This intermediary material absorbs or blocks the laser beam, preventing it from reaching and damaging the internal surfaces on the opposite side of the component.
2Reliability
If laser-blocking material is injected into the workpiece, then laser beam penetration is prevented, but air bubbles in the material cause defects
Solution Approach 1:
The patent applies parameter changes by controlling the viscosity and temperature of the laser-blocking material during injection. By adjusting these parameters, the material achieves optimal flow characteristics for complete fill without trapping air bubbles, ensuring both reliable laser blocking and high manufacturing precision.
Solution Approach 2:
The patent utilizes phase transitions of the laser-blocking material (from liquid/molten state during injection to solid state after setting) to achieve proper filling. The material is injected in a fluid phase that allows complete penetration into passageways, then transitions to a solid phase that provides effective laser blocking without trapped air bubbles.
3Manufacturing precision
If the workpiece is subjected to partial vacuum during material injection, then air bubbles are expanded and removed, but the process complexity increases
Solution Approach 1:
The patent applies pneumatic principles by using a partial vacuum environment during material injection. The reduced pressure causes air bubbles to expand and rise to the surface, where they can be removed, while the material continues to flow and fill the passageways completely. This pneumatic approach achieves excellent bubble removal with relatively simple equipment.
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 method effectively prevents laser beam penetration, reducing the risk of damage to internal surfaces, increasing the efficiency of the drilling process by ensuring air bubble-free fill and rapid cycle times, and allowing for the reuse of the hardened laser-blocking material.
Implementation Method 1
subjecting the workpiece to an at least partial vacuum within the enclosed environment such that air bubbles in the laser-blocking material are expanded and transported out
Data Source
AI summary
A method of injecting laser-blocking material into a workpiece includes communicating molten laser-blocking material through the workpiece as the workpiece is subjected to at least a partial vacuum within an enclosed environment such that the partial vacuum expands any air bubbles in the laser-blocking material and transports the air bubbles out of the workpiece.