Ultrafast laser processing of shaped film cooling holes for aero-turbine blades: Surface integrity, parameter influence and forming mechanism

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes Pub Date : 2025-07-10 DOI:10.1016/j.jmapro.2025.07.017

Meng Li , Zhixun Wen , Ping Wang , Yuxing Liu , Zhufeng Yue

{"title":"Ultrafast laser processing of shaped film cooling holes for aero-turbine blades: Surface integrity, parameter influence and forming mechanism","authors":"Meng Li , Zhixun Wen , Ping Wang , Yuxing Liu , Zhufeng Yue","doi":"10.1016/j.jmapro.2025.07.017","DOIUrl":null,"url":null,"abstract":"<div><div>Shaped film cooling holes (FCHs) can effectively improve the film cooling efficiency of turbine blades, but due to their complex structure and precision requirements, there is currently no reliable and high-quality machining method. In this paper, a segmented processing method of fan-shaped FCHs is proposed, which realizes high-quality processing of fan-shaped FCHs. The effects of processing parameters on the machining efficiency, geometric accuracy and surface morphology of fan-shaped FCHs were analyzed. And the microstructure, composition, surface roughness and residual stress of the hole wall under specific processing parameters were characterized. The influence mechanism of processing parameters on the processed results is clarified by laser overlap rate and laser energy density of the processing area. The important role of focus compensation in the segmented machining method is discussed. The formation mechanism of microstructures was explained by the plasma exciton theory and the energy shielding effect. Furthermore, the process method is promoted through expansion section model segmentation and processing attitude adjustment to realize the processing of cat-ear-shaped and bat-face-shaped FCHs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1194-1215"},"PeriodicalIF":6.1000,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Processes","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S1526612525007868","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}

引用次数: 0

Abstract

Shaped film cooling holes (FCHs) can effectively improve the film cooling efficiency of turbine blades, but due to their complex structure and precision requirements, there is currently no reliable and high-quality machining method. In this paper, a segmented processing method of fan-shaped FCHs is proposed, which realizes high-quality processing of fan-shaped FCHs. The effects of processing parameters on the machining efficiency, geometric accuracy and surface morphology of fan-shaped FCHs were analyzed. And the microstructure, composition, surface roughness and residual stress of the hole wall under specific processing parameters were characterized. The influence mechanism of processing parameters on the processed results is clarified by laser overlap rate and laser energy density of the processing area. The important role of focus compensation in the segmented machining method is discussed. The formation mechanism of microstructures was explained by the plasma exciton theory and the energy shielding effect. Furthermore, the process method is promoted through expansion section model segmentation and processing attitude adjustment to realize the processing of cat-ear-shaped and bat-face-shaped FCHs.

查看原文本刊更多论文

航空涡轮叶片形膜冷却孔的超快激光加工：表面完整性、参数影响及形成机理

异形气膜冷却孔（FCHs）可以有效提高涡轮叶片的气膜冷却效率，但由于其结构复杂、精度要求高，目前还没有可靠、高质量的加工方法。本文提出了扇形FCHs的分段加工方法，实现了扇形FCHs的高质量加工。分析了加工参数对扇形FCHs加工效率、几何精度和表面形貌的影响。并对不同工艺参数下孔壁的显微组织、成分、表面粗糙度和残余应力进行了表征。通过激光重叠率和加工区激光能量密度，阐明了加工参数对加工结果的影响机理。讨论了焦点补偿在分段加工方法中的重要作用。用等离子体激子理论和能量屏蔽效应解释了微结构的形成机理。进一步，通过展开截面模型分割和加工姿态调整，推进加工方法，实现对猫耳形和蝙蝠面形FCHs的加工。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-

CiteScore

10.20

自引率

11.30%

发文量

833

审稿时长

50 days

期刊介绍： The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.