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Deep Observation: The Application of Laser in Aerospace Manufacturing (Part 3)
2023-07-1948

Laser drilling

 

Modern aviation engines have approximately 500000 holes, approximately 100 times the number of engines manufactured in the 1980s. At the same time, aircraft manufacturers are also producing an increasing number of other components, which require extensive drilling for riveting and screw connections. Therefore, in the aviation industry, laser drilling has enormous market potential because it provides precise, repeatable, fast, and cost-effective processes.

For example, a new high-power femtosecond laser system is being developed for efficient and accurate micro drilling on large titanium HLFC (mixed laminar flow control) panels that will be mounted on wings or tail stabilizers. These panels absorb air through small holes, thereby reducing frictional resistance and reducing fuel consumption.

 

Due to the non-contact nature of laser drilling, the processed material does not need to be fixed in the same way as traditional tool processing. Another advantage of non-contact is that it does not cause tool wear, which represents a special advantage in drilling CFRP components. Due to its hardness, CFRP components can cause significant wear on traditional tools. Laser drilling can also be carried out at very high speeds, so excessive heat damage will not cause damage to the material being processed.

 

Additive manufacturing

 

Laser additive manufacturing (AM) has also developed rapidly in the aerospace industry. In this technology, laser melts continuous powder layers to construct shapes. A rocket company based in California recently even ordered two 12 laser beam 3D printers to make its space missions more economical and efficient by manufacturing lighter, faster, and more robust space components.

 

Although many projects are still in the testing stage, laser additive manufacturing has been successfully used in two Mars missions. NASA's Curiosity Mars rover landed in August 2012, the first mission to Mars with 3D printing components. This is a ceramic component within the Mars Sample Analysis (SAM) instrument, which is part of an ongoing testing plan to investigate the reliability of additive manufacturing technology.

 

Meanwhile, NASA's Persevere spacecraft landed on Mars in February 2021, containing 11 metal components made of laser additive materials. Five of the components are in the X-ray Lithochemical Planet Instrument (PIXL) of the Persevere spacecraft, which is searching for signs of microbial fossil life on Mars. These components need to meet very light standards, to the extent that traditional forging, molding, and cutting technologies cannot be produced.

 

NASA has also been experimenting with the use of laser additives to manufacture rocket components. In one study, the combustion chamber of a rocket engine was made of copper alloy. The continuous development of laser additive manufacturing has resulted in the manufacturing cost of this component being approximately half of the cost required for traditional processing, connection, and assembly, with only one sixth of the time required for traditional processing, connection, and assembly. Due to the strong reflectivity of the copper alloy used in infrared lasers, NASA is currently studying how green or blue lasers can improve efficiency and productivity.

 

Although the application of additive manufacturing in the aerospace industry is still in its early stages, it is expected to grow in the next 20 years.

 

Laser texturing

 

Laser texturing is also a very new application in the aerospace industry. In this process, ultrafast laser is used to generate micro and nanostructures on the surface of aircraft through a technology called Direct Laser Interference Pattern (DLIP), which is used to create a natural "lotus effect". The nanostructures created by this technology help prevent surface pollution and prevent ice accumulation on the aircraft.

 

Innovative optics divide a powerful ultrafast laser pulse into several parts of the beam, which are then combined on the processed surface. When observed under a microscope, the resulting microstructure resembles a microscopic "hall" composed of "columns" or ripples. The distance between the 'pillars' is approximately 150nm to 30 μ Between m - This structure means that water droplets no longer wet the surface and stick to it because they do not have sufficient grip on the surface.

 

The benefits of this material for airplanes include increased resistance to water, ice, and insects. These can all stick to the surface of the aircraft and increase its wind resistance, thereby increasing fuel consumption. Applying this laser texture will reduce the need for toxic chemical treatment currently applied to aircraft surfaces to avoid icing. As is well known, over time, it will age and be easily damaged. In addition, laser structures produced using the DLIP method can last for several years without causing environmental problems.

 

About HGTECH

HGTECH is the pioneer and leader of laser industrial application in China, and the authoritative provider of global laser processing solutions. We comprehensively layout the construction of laser intelligent equipment, measurement and automation production lines, and smart factories to provide an overall solution for intelligent manufacturing.

We deeply grasp the development trend of manufacturing industry, constantly enrich products and solutions, adhere to exploring the integration of automation, informatization, intelligence and manufacturing industry, and provide various industries with laser cutting systems, laser welding systems, laser marking series, laser texturing complete equipment, laser heat treatment systems, laser drilling machines, lasers and various supporting devices The overall plan for the construction of special laser processing equipment and plasma cutting equipment, as well as automatic production lines and smart factories.