飞秒激光加工镍基合金无锥度微孔试验研究(封面文章·特邀)  

Experimental study on femtosecond laser processing non-taper microholes in nickel-based alloys(cover paper·invited)

作　　者：张书愿 周熙杰 崔健磊[1] 范润泽 谢合瑞 梅雪松[1] ZHANG Shuyuan;ZHOU Xijie;CUI Jianlei;FAN Runze;XIE Herui;MEI Xuesong(State Key Laboratory for Manufacturing Systems Engineering,Xi’an Jiaotong University,Xi’an 710054,China;Xi’an Space Engine Co.Ltd.,Xi’an 710061,China)

机构地区：[1]西安交通大学机械制造系统工程国家重点实验室,陕西西安710054 [2]西安航天发动机有限公司,陕西西安710061

出　　处：《红外与激光工程》2024年第11期1-10,I0003,共11页Infrared and Laser Engineering

基　　金：航空发动机及燃气轮机基础科学中心重大项目(P2022-A-IV-002-003);国家重点研发计划项目(2023YFB4605100);陕西省重点研发计划项目(2021ZDLGY10-02)。

摘　　要：随着我国航空航天事业的不断发展,镍基合金等耐高温材料和气膜冷却技术逐渐应用于航空发动机的热端部件中,对航空发动机热端部件气膜孔的制造要求也日益提高,电火花和电化学等传统加工方法已无法满足在镍基合金上加工高质量微孔的制造要求。而飞秒超快激光由于其精密、低损伤、冷加工的特点,越来越契合镍基合金微孔的加工需求,但是在加工大深径比微孔时出现的热缺陷、锥度不足等问题仍然需要克服。针对镍基合金材料深微孔加工难题,基于倾斜工件旋转钻孔的激光加工工艺,首先阐述了加工方法和试验原理,然后在镍基合金材料上开展了无锥度单孔加工试验,采用控制变量法探究了激光离焦量、激光重复频率、激光扫描半径和激光光轴偏移量对单孔形貌的影响规律,在2 mm厚度镍基合金上实现了无锥度的高质量单孔加工。为了解决较厚材料的大深径比无锥度微孔加工问题,在倾斜工件旋转钻孔的基础上进行了工艺优化,采用钻孔、扩孔、修孔三道工序,并增加了旁轴吹气辅助工艺,从而在6 mm厚度镍基合金上实现了锥度为0.14°的深微孔加工。Objective With the development of the aerospace field,high temperature resistant materials such as nickelbased alloys and gas film cooling holes are gradually applied to the hot end parts of aero engines,and the manufacturing requirements for the gas film holes of the hot end parts of aero engines are also increasing.Traditional processing methods such as EDM and electrochemistry can no longer meet the manufacturing requirements for machining high-quality microholes on nickel-based alloys.Due to its precision,low damage and cold processing characteristics,femtosecond ultrafast laser is increasingly suitable for the processing of nickelbased alloy microholes,but the problems such as thermal defects and insufficient taper in the processing of large depth to diameter microholes still need to be overcome.To solve the taper problem of nickel-based alloy material deep microhole machining,the femtosecond laser machining of nickel-based alloy without taper single hole experiment was carried out in this paper.Methods A femtosecond laser numerical control machining system(Fig.1)is adopted to carry out non-taper single-hole machining experiments on nickel-based alloy materials based on the laser processing technology of rotating drilling of inclined workpieces.The influence rules of laser defocusing amount,laser repetition frequency,laser scanning radius and laser optical axis offset on single-hole morphology are investigated by using the control variable method,and then the process is optimized.Three processes of drilling,reaming and repairing are adopted(Tab.3),and an auxiliary device for side-shaft blowing is added(Fig.8).Results and Discussions The effects of laser defocusing amount(Fig.4),laser repetition frequency(Fig.5),laser scanning radius(Fig.6)and laser optical axis offset(Fig.7)on the morphology of single hole are investigated,the optimal process parameters are obtained,and high-quality single hole machining with a taper of 0.04°is realized on nickel-based alloy with 2 mm thickness.On the basis of process optim

关 键 词：飞秒激光 镍基合金 微孔加工 锥度调控 

分 类 号：TN249[电子电信—物理电子学]