Laser Hole Production Using Variable Pulse Lengths
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Solution Overview
Problem
The existing methods for producing holes in turbine components, particularly film-cooling holes, using ultrashort laser pulses are expensive and time-consuming due to their low mean powers and the need for precise laser pulse lengths to avoid inhomogeneous cut surfaces and cracks.
Innovation Solution
The process employs different laser pulse lengths, using very short pulses for the outer upper region to ensure accurate geometry and prevent cracks, and longer pulses for the interior, allowing for efficient production of holes with minimal fusion and accurate geometries, while an apparatus with adjustable laser beams facilitates this process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultrashort laser pulses are used for hole production, then manufacturing precision is improved, but productivity deteriorates due to low mean powers and time-consuming processes
Solution Approach 1:
The hole production process is divided into multiple sequential steps, each using laser pulses of different durations optimized for that specific stage. The first step uses longer pulses for initial material removal, followed by subsequent steps using shorter pulses for precision finishing. This segmentation allows each step to operate at optimal parameters, improving both precision and overall productivity.
Solution Approach 2:
The laser pulse duration is dynamically adjusted based on the production stage and required precision. The system transitions from longer pulse durations in early stages to shorter pulse durations in later stages, optimizing the balance between material removal efficiency and geometric precision throughout the manufacturing process.
2Manufacturing precision
If short laser pulse lengths are used throughout the process, then manufacturing precision is improved, but productivity deteriorates due to low mean powers
Solution Approach 1:
Different laser pulse durations are applied to different regions and stages of the hole production process. Longer pulses are used for bulk material removal where precision requirements are lower, while shorter pulses are used for final surface finishing where precision is critical. This local optimization of pulse duration matches the quality requirements of each specific region.
3Productivity
If longer laser pulse lengths are used, then productivity is improved through higher mean powers, but manufacturing precision deteriorates due to inhomogeneous cut surfaces
Solution Approach 1:
The process segments hole production into distinct phases: a roughing phase using longer pulses for efficient material removal, and a finishing phase using shorter pulses for precision surface quality. This segmentation allows the system to exploit the productivity advantage of long pulses while mitigating their precision disadvantages through subsequent precision processing.
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 enables the quick and cost-effective production of holes with precise geometries and reduced material defects, improving the flow properties of media through and around the holes, and can be applied to both new and refurbished components.
Implementation Method 1
a hole is produced in a component by at least one laser and pulsed laser beams
Data Source
AI summary
Previous methods for the production of a hole in a component are very time-consuming and expensive, as special lasers having ultra short laser pulse lengths are used. The inventive method varies laser pulse lengths and ultra short laser pulse lengths are used exclusively in the region which is to be removed, wherein it is possible to have a noticeable influence on through flow and/or out-flow behavior. This, for example, the inner surface of a diffuser of a hole, which can be produced in a precise manner using ultra short laser pulse lengths.