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Laser Drilling of Superalloys and Composites

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Additive and Subtractive Manufacturing of Composites

Part of the book series: Springer Series in Advanced Manufacturing ((SSAM))

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Abstract

Unique properties such as high strength, wear and fatigue resistance at high temperatures have made superalloys best candidate materials for the aerospace industry. On the other hand, the development of composite materials particularly metal matrix composites (MMCs) have comparable properties to superalloys and have an advantage of being lightweight and high strength to wear ratio. A significant application involves the use of superalloys and composites in aerospace gas turbine components used in high-temperature applications. The mechanical machining of these materials is difficult due to higher tool wear and low material removal rate. Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components, in particular high-pressure turbine blades, combustors and nozzle guide vanes. High-value manufacturing industries always aim to improve process efficiency and produce parts at the lowest possible cost without affecting product quality. Taking into account the significance of these factors this chapter focuses on material removal volume, different hole quality attributes and manufacturing cost as performance measures to study the impacts of laser drilling process parameters for the selected materials. Conclusively, some future perspectives concerning the use of laser drilling are highlighted, specifically with advancements in science and technology.

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Abbreviations

\(A\) :

Material absorptivity

\(A_{{\text{s}}}\) :

Cross-sectional area of the laser spot (mm2)

\(D_{Max}\) :

Maximum hole diameter (mm)

\(D_{Min}\) :

Minimum hole diameter (mm)

\(D_{ent}\) :

Entrance hole diameter (mm)

\(D_{ex}\) :

Exit hole diameter (mm)

\(D_{p}\) :

Pulse duration (s)

\(E_{abs}\) :

Energy absorbed by the material (J)

\(F_{l}\) :

Focal length (mm)

\(H_{c}\) :

Hole circularity

\(P\) :

Applied laser power (W)

\(P_{d}\) :

Laser power density (W/mm2)

\(P_{e}\) :

Pulse energy (J)

\(S_{d}\) :

Spot diameter (mm)

\(t\) :

Material thickness (mm)

\(\theta\) :

Taper angle

\(\emptyset\) :

Beam divergence (angle)

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Authors and Affiliations

  1. Manufacturing Department, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, MK43 0AL, Bedfordshire, UK

    Shoaib Sarfraz, Konstantinos Salonitis & Wojciech Suder

  2. Mechanical and Aerospace Engineering Department, School of Engineering and Digital Sciences, Nazarbayev University, Nur-Sultan, 010000, Kazakhstan

    Essam Shehab

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  1. Shoaib Sarfraz
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Correspondence to Shoaib Sarfraz .

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  1. Natural Composites Research Group Lab, Department of Materials and Production Engineering, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok, Thailand

    Sanjay Mavinkere Rangappa

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, China

    Munish Kumar Gupta

  3. Natural Composites Research Group Lab, Department of Materials and Production Engineering, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut’s University of Technology North Bangkok (KMUTNB), Bangkok, Thailand

    Suchart Siengchin

  4. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, China

    Qinghua Song

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Sarfraz, S., Shehab, E., Salonitis, K., Suder, W. (2021). Laser Drilling of Superalloys and Composites. In: Mavinkere Rangappa, S., Gupta, M.K., Siengchin, S., Song, Q. (eds) Additive and Subtractive Manufacturing of Composites. Springer Series in Advanced Manufacturing. Springer, Singapore. https://doi.org/10.1007/978-981-16-3184-9_5

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