Patent Application
20230219168
A gas turbine engine typically includes a fan section, a compressor section, a combustor section and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-pressure and temperature exhaust gas flow. The high-pressure and temperature exhaust gas flow expands through the turbine section to drive the compressor and the fan section. The compressor section may include low and high pressure compressors, and the turbine section may also include low and high pressure turbines.
Airfoils in the turbine section and components in other hot sections of the engine are typically formed of a superalloy and may include thermal barrier coatings to extend temperature capability and lifetime. Ceramic materials (e.g., monolithic and ceramic matrix composites) are also being considered for these components. Among other attractive properties, ceramics have high temperature resistance. It has been a challenge, however, to develop efficient processes to machine features, such as cooling holes and slots, into ceramic components.
A waterjet-guided laser machine according to an example of the present disclosure includes a laser source operable to emit a pulsed laser beam, a light-emitting diode (LED) operable to emit a light beam different than the pulsed laser beam, a waterjet head including an inlet for receiving water and a nozzle having an outlet for a discharging a jet of the water therefrom, a light sensor, a laser optical path along which the pulsed laser beam travels from the laser source, through the nozzle and to the nozzle outlet, and a light beam optical delivery path along which the light beam travels from the LED, through the nozzle and to the nozzle outlet. The light beam optical delivery path is coincident with the laser optical path inside of the nozzle. A light beam optical return path along which a portion of the light beam that is reflected off of a workpiece travels from the nozzle outlet and back through the nozzle to the light sensor. The light beam optical return path is coincident with the laser optical path inside the nozzle and coincident with the light beam optical delivery path inside the nozzle.
In a further embodiment of any of the foregoing embodiments, the laser optical path contains, in order from the laser source to the waterjet head, a first lens, a first mirror, a second mirror, and a second lens.
In a further embodiment of any of the foregoing embodiments, the light beam optical delivery path is coincident with the with the laser optical path from the second mirror to the second lens and from the second lens to the waterjet head, and the laser optical path is non-coincident with the with the light beam optical delivery path from the laser source to the first lens, from the first lens to the first mirror, and from the first mirror to the second mirror.
In a further embodiment of any of the foregoing embodiments, the light beam optical return path is coincident with the with the laser optical path from the waterjet head to the second lens, from the second lens to the second mirror, and from the second mirror to the first mirror.
In a further embodiment of any of the foregoing embodiments, the light beam optical return path includes a third mirror, and the light beam optical return path is non-coincident with the laser optical path from the first mirror to the third mirror and from the third mirror to the light sensor.
In a further embodiment of any of the foregoing embodiments, the LED is operable to emit the light beam having a wavelength of 495-570 nanometers.
A further embodiment of any of the foregoing embodiments includes an electronic controller operably connected with at least the laser source, the LED, and the light sensor.
In a further embodiment of any of the foregoing embodiments, the light sensor is operable to emit sensor signals responsive to the portion of the light beam received into the light sensor from the light beam optical return path, and the electronic controller is configured to determine from the sensor signals a depth-of-cut of the laser beam into the workpiece.
In a further embodiment of any of the foregoing embodiments, the electronic controller is configured to adjust scan rate of movement of the laser beam relative to the workpiece along a cutting path based upon the depth-of-cut.
In a further embodiment of any of the foregoing embodiments, the electronic controller is configured to identify a fault condition if the depth-of-cut is below a threshold over a preset duration.
In a further embodiment of any of the foregoing embodiments, the electronic controller is configured to pulse the light beam in coordination with the pulsed laser beam such that during an OFF period of the pulsed laser beam the light beam is ON and during an ON period of the pulsed laser beam the light beam if OFF.
A further embodiment of any of the foregoing embodiments includes an acoustic sensor operable to emit acoustic sensor signals responsive to receiving sound emitted from the workpiece, and the electronic controller is configured to determine an initiation of cutting of the workpiece by the laser based on the acoustic sensor signals.
In a further embodiment of any of the foregoing embodiments, the electronic controller is configured to determine the initiation of the cutting of the workpiece by the laser based on the frequency of the acoustic sensor signals.
A method of machining a workpiece in a waterjet-guided laser machine according to an example of the present disclosure includes discharging a jet of water from a nozzle outlet of a waterjet head. The jet impinges the workpiece. A pulsed laser beam is emitted from a laser beam source along a laser optical path through the nozzle and to the nozzle outlet such that the pulsed laser beam is guided in the jet of water and also impinges the workpiece. A light beam that is different than the laser beam is emitted from a light-emitting diode (LED) along a light beam optical delivery path through the nozzle and to the nozzle outlet. The light beam optical delivery path is coincident with the laser optical path inside of the nozzle. A light sensor receives a portion of the light beam that is reflected off of the workpiece along a light beam optical return path from the nozzle outlet and back through the nozzle. The light sensor emits sensor signals responsive to the portion of the light beam that is received. The light beam optical return path is coincident with the laser optical path inside the nozzle and coincident with the light beam optical delivery path inside the nozzle. The signals are used as feedback in an electronic controller to adaptively adjust the cutting of the workpiece by the laser beam.
In a further embodiment of any of the foregoing embodiments, the electronic controller determines from the sensor signals a depth-of-cut of the laser beam into the workpiece.
In a further embodiment of any of the foregoing embodiments, the electronic controller adjusts a scan rate of the movement of the laser beam relative to the workpiece along a cutting path based upon the depth-of-cut.
In a further embodiment of any of the foregoing embodiments, the electronic controller identifies a fault condition if the depth-of-cut is below a threshold over a preset duration.
In a further embodiment of any of the foregoing embodiments, the electronic controller pulses the light beam in coordination with the pulsed laser beam such that during an OFF period of the pulsed laser beam the light beam is ON and during an ON period of the pulsed laser beam the light beam if OFF.
The present disclosure may include any one or more of the individual features disclosed above and/or below alone or in any combination thereof.
The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
Components in gas turbine engines, such as but not limited to, turbine blades, turbine vanes, blade outer air seals, and combustor panels, include cooling holes, slots, and other relatively small-scale features. Such features may be formed in a machining operation after manufacture of the base component. However, when the component is made of ceramic material, such as monolithic ceramic or ceramic matrix composite (CMC), efficient machining is a challenge because ceramics are extremely hard and brittle.
Waterjet-guided laser machining (WJGM) is one process that is under consideration for producing such features. In general, WJGM involves a laser beam that is guided by internal reflection in a narrow jet of water to impinge upon a workpiece. The laser beam ablates the surface of the workpiece, thereby removing material. The waterjet may be scanned across the surface of the workpiece in multiple passes to remove material layer-by-layer and thereby form a hole, slot, or other feature. In comparison to other machining processes, WJGM generally has high accuracy, long working distance, and low thermal load on the workpiece. Deviations in process parameters can sometimes result in features that exceed desired tolerances, especially for the manufacturing of precision components. As a consequence, the process window, i.e., the range of permissible parameter deviations, is often narrow. To a limited extent, acoustic emission, laser triangulation, and capacitive sensors may be used to monitor the process. However, further improvements in process monitoring and process control are desired for higher precision, rapid cycle times, and higher efficiency, particularly for the machining of ceramic materials.
In these regards,
The machine 20 includes a laser source 22, a light-emitting diode (LED) 24, a waterjet head 26, an electronic controller 28, a light sensor 30, and an acoustic sensor 32. The controller 28 may include hardware, such as one or more microprocessors, software, or both that is configured to control the operation of the machine 20 and carry out the functions described in this disclosure. In the illustrated example, the controller 28 is self-contained in the machine 20, although it is also contemplated that portions of the controller 28 may be in one or more separate electronic devices, such as computers, tablets, or the like. As will be described, the acoustic sensor 32 may provide additional monitoring and control capability, but if such capability is not desired the acoustic sensor 32 may be excluded.
The controller 28 is connected with the laser source 22, LED 24, light sensor 30, and acoustic sensor 32 for component control and communication, such as ON/OFF modes of the laser source 22 and the LED 24, ON/OFF modes of the light sensor 30 and acoustic sensor 32, and receipt of electronic feedback signals from the light sensor 30 and acoustic sensor 32. As will be appreciated, the machine 20 may include additional components that are known for waterjet-guided laser equipment, such as but not limited to, mounts or the like for holding a workpiece, an actuator or actuators for moving the workpiece relative to the laser beam, a gas source for delivery and use of process gas, etc.
The laser source 22 is operable to emit a pulsed laser beam 34, and the LED 24 is operable to emit a light beam 36 (different than the pulsed laser beam 34). For example, the light beam 36 has a wavelength of 495-570 nanometers (in the green portion of the spectrum). The waterjet head 26 includes an inlet 26a for receiving water and a nozzle 26b having an outlet 26c for a discharging a high-pressure waterjet 38 therefrom. For example, waterjet pressures may be 50-800 bar, and the diameter of the waterjet 36 may be 25-100 micrometers. The light sensor 30 includes a photodiode that is responsive in the applicable wavelength range for producing electronic sensor signals representative of the intensity of light received thereto. In a further example, the photodiode may be integrated into a camera that also provides visual feedback of the process.
The laser beam 34 emitted from the laser source 22 travels along a laser optical path 34a from the laser source 22, through the nozzle 26b, to the nozzle outlet 26c and then to the workpiece (W). The light beam 36 emitted from the LED 24 travels along a light beam optical delivery path 36a from the LED 24, through the nozzle 26b, to the nozzle outlet 26c and then to the workpiece (W). The light beam optical delivery path 36a is coincident with the laser optical path 34a at least inside of the nozzle 26b (i.e., “inline”).
There is also a light beam optical return path 36b along which a portion of the light beam 36 that is reflected off of a workpiece (W) travels back through the nozzle outlet 26c and back through the nozzle 26b to the light sensor 30. The light beam optical return path 34b is coincident with the laser optical path 34a at least inside the nozzle 26b and is coincident with the light beam optical delivery path 36a at least inside of the nozzle 26b.
The paths 34a/36a/36b are designated in
As illustrated, the machine 20 also includes optical components for manipulating the beams 34/36 and fixing the beam paths 34a/36a/36b. For instance, the laser optical path 34a contains, in order from the laser source 22 to the waterjet head 26, a first lens 40, a first mirror 42, a second mirror 44, and a second lens 46. The lenses 40/44 serve to focus the beam or beams, and the mirrors 42/46 redirect the beam or beams. As an example, the mirrors 42/46 may be dichromic mirrors such that one beam is reflected and another transmitted there through.
In the example shown, the light beam optical delivery path 36a is coincident with the with the laser optical path 34a from the second mirror 44 to the second lens 46 and from the second lens 46 to the waterjet head 26. The laser optical path 34a is non-coincident with the with the light beam optical delivery path 36a from the laser source 22 to the first lens 40, from the first lens 40 to the first mirror 42, and from the first mirror 42 to the second mirror 44. The light beam optical return path 36b is coincident with both the light beam optical delivery path and the laser optical path 34a from the waterjet head 26 to the second lens 46 and from the second lens 46 to the second mirror 44. The light beam optical return path 36b is coincident with the laser optical path 34a from the second mirror 44 to the first mirror 42. The light beam optical return path 36b includes a third mirror 48 and a third lens 50. The light beam optical return path 36b is non-coincident with the laser optical path 34a from the first mirror 42 to the third mirror 48 and from the third mirror 48 to the third lens 50 and the light sensor 30. The configuration above permits the LED 24, laser source 22, and light sensor 30 to be spatially separated in the machine 20, yet still allow optical inline integration of the beams 34/36.
In the machining of the workpiece (W), the controller 28 activates the laser source 22 and the LED 24. The laser beam 34 is pulsed at a preset frequency between ON/OFF modes. The controller 28 also pulses the light beam 36 in coordination with the pulses of the laser beam 34 such that during an OFF period of the laser beam 34 the light beam 36 is ON and during an ON period of the laser beam 34 the light beam 36 if OFF.
In the waterjet head 26, the laser beam 34 couples with the waterjet 38 by internal reflection. The waterjet 38 and laser beam 34 impinge upon the workpiece (W). The laser beam 34 ablates the surface of the workpiece (W), thereby removing material. The controller 28 is also configured to move the laser beam 34 relative to the workpiece (W) along a pre-programmed cutting path such that the waterjet 38, and thus also the laser beam 34, scans across the surface of the workpiece (W) to remove material layer-by-layer and thereby form a hole, slot, or other feature in the workpiece (W).
The light beam 36 also impinges the surface of the workpiece (W). At least a portion of the light beam 36 reflects off of the surface and back along the light beam optical return path 36b to the light sensor 30. Responsive to the received reflected light beam 36, the light sensor 30 generates sensor signals that are communicated to the controller 28 as process feedback. The controller 28 is configured to analyze the sensor signals and determine a depth-of-cut of the laser beam 34 into the workpiece (W). For example, the sensor signals are processed via Fourier transform to identify a signal peak or peaks that correspond to the depth-of-cut.
The feedback provided by the sensor signals may be used in real-time by the controller 28 to control and adapt operation of the machine 20. For instance, in a comparison process, the waterjet and laser are scanned across the surface at a preset scan rate. The preset scan rate, however, does not account for the actual depth-of-cut. Therefore, due to process variation, in some locations the depth-of-cut may be shallower than desired while in other locations the depth-of-cut may be deeper than desired. In contrast, the real-time monitoring of the actual depth-of-cut via the feedback sensor signals facilitates dynamic adaptation of the scan rate to achieve a more accurate depth-of-cut. For instance, if the depth-of-cut is shallower than an expected depth-of-cut the controller 28 may decrease scan rate in order to increase depth-of-cut, or if the depth-of-cut is deeper than expected the controller 28 may increase scan rate in order to decrease depth-of-cut. As will be appreciated, thresholds for deviation from expected depths-of-cut and resulting adjustment to the scan rate may be programmed into the controller 28 in accordance with the particular implementation. It is also to be appreciated that the adaptive adjustment is not limited to scan rate, and that other parameters such as laser power, process water pressure, and/or process water flow (singularly or collectively “process parameters”) may be changed in response to the feedback sensor signals.
The controller 28 may also utilize the depth-of-cut feedback as a process fail-safe. For example, once the laser beam 34 is ON, material removal is expected. However, if the feedback indicates that there is no change in the depth-of-cut, such as when the change in the depth-of-cut is below a threshold over a preset time duration, the controller identifies this as a fault condition. In response to the fault condition, the controller 28 may trigger an alert and/or switch the laser source 22 to the OFF mode.
The acoustic sensor 32, if used, may provide additional feedback for process control. The interaction of the laser beam 34 with the workpiece (W) produces acoustic waves. These acoustic waves are received by the acoustic sensor 32, which responsively produces acoustic sensor signals that are communicated to the controller 28 as feedback. In an amplitude/time domain, it can be challenging to identify signal characteristics that represent relevant process parameters, such as the initiation of cutting of the workpiece (W) by the laser beam 34. However, analysis of the acoustic sensor signals in a frequency/time domain by fast Fourier transform produces distinct peaks that are indicative of relevant process parameters, such as the initiation of cutting of the workpiece (W) by the laser beam 34. In this regard, the controller 28 is configured to precisely determine the initiation of cutting of the workpiece (W) by the laser beam 34 based on the acoustic sensor signals. The controller 28 then utilizes the identification of the initiation of cutting to coordinate the pulses of the light beam 36 and the laser beam 34. Thus, as the pulse frequency of the laser beam 34 is known, once initiation of cutting is determined the pulses of the light beam 36 can be initiated out-of-phase with the laser pulses. Such coordination facilitates good signal fidelity by reducing interference between the reflected light beam 36 and the laser beam 34. The acoustic sensor signals may additionally or alternatively be used to identify other characteristics. For example, the “break-through” of cutting a through-hole results in a distinct change in the acoustic signal that can then be used to identify the completion of the cutting process and ceasing of the laser beam 34. Moreover, as the beam paths 34a/36a/36b are coincident over much of their extent, the machine 20 can be compact in size. Additionally, existing waterjet-guided laser machines may even be retrofit in accordance with this disclosure and with the addition of relatively few components.
During the cutting process, there is Real-time Process Monitoring. Such monitoring may include, identification of the instant working step in the process, signal analysis, inline optical measurement (e.g., position, depth, and uncertainty), and integration of sensor results. The acoustic sensor signals are captured to detect the beginning of machining, which is then used to trigger the inline optical depth measurement. Also, with position data from the controller 28, the current working step can be identified together with the associated features that are being cut. By including the context information of current machined features, all machining data can be captured using the in-situ measurement system. With the measured data together with the process context information, it is possible to correlate the signals with variations in the cutting parameters, such as laser power, process water pressure, cutting velocity, or water flow rate to facilitate process optimization.
Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
