Insights into drilling film cooling holes on ceramic‑coated nickel‑based superalloys

Vasudevan, Balaji; Natarajan, Yuvaraj; Sivalingam, Vinothkumar; Krolczyk, Grzegorz; Tandon, Puneet

doi:10.1007/s43452-022-00465-x

Artykuł - szczegóły

Tytuł artykułu

Insights into drilling film cooling holes on ceramic‑coated nickel‑based superalloys

Autorzy

Vasudevan Balaji , Natarajan Yuvaraj , Sivalingam Vinothkumar , Krolczyk Grzegorz , Tandon Puneet

Wybrane pełne teksty z tego czasopisma

http://www.springer.com/journal/43452

Identyfikatory

DOI

10.1007/s43452-022-00465-x

Warianty tytułu

Języki publikacji

Abstrakty

This article aims at providing insights into various drilling operations relating to the production of holes of small diameter for film cooling, particularly inclined holes, in aero-engine turbine blades, made of Yttria-stabilized Zirconia (YSZ) coated superalloy. Drilling inclined holes on YSZ coated superalloys that find use in aerospace industries is difficult due to the presence of two sections of materials, each section possessing different material properties. This article indicates five machining processes, namely conventional drilling, electrical discharge drilling, laser drilling, electro chemical discharge machining (ECDM), and abrasive water jet machining (AWJM). Machinability and the challenges involved in the fabrication of micro straight and inclined holes on ceramic-coated nickel-based superalloys have been discussed. Previous researchers have attempted at drilling tiny holes (≤ 2 mm) on ceramic-coated and uncoated nickel-based superalloys at different hole angles varying from 10° to 90°. Material removal was seen as difficult to control in the YSZ coated section when compared to the superalloys. Despite the occurrence of a controlled manner of material removal in different machining techniques, the holes produced had poor geometry and surface finish with cavities on the ceramic coat and burr formation at the hole exit. There was also the problem of thermal spalling, delamination, flakes, spatters, recast layer and cracks seen over the ceramic coat due to the employment of thermal-based machining techniques including laser drilling with advanced pulse settings. Keeping this in view, the AWJM technique is found to be a good alternative technique for drilling inclined holes with size constraints as the cold process maintains material integrity, followed by the ECDM and the conventional drilling processes. However, the hybrid process, namely ECDM, has still been a complex phenomenon in the material removal mechanism of the YSZ coated section consuming a lot of time. Based on the key results from the different setups, the outcome of this work provides a platform for scientists and engineers working in aerospace industries for finding a suitable machining process for drilling precision holes on the YSZ coated nickel-based superalloys.

Słowa kluczowe

yttria stabilized zirconia inclined hole turbine blade machining technique

dwutlenek cyrkonu stabilizowany itrem łopatka turbiny technologia obróbki

Wydawca

Springer
Wrocław University of Science and Technology

Czasopismo

Archives of Civil and Mechanical Engineering

Rocznik

2022

Tom

Vol. 22, no. 3

Strony

art. no. e141

Opis fizyczny

Bibliogr. 59 poz., rys., tab.

Twórcy

autor

Vasudevan Balaji

Department of Mechanical Engineering, Vel Tech Rangarajan Dr, Sagunthala R&D Institute of Science and Technology, Avadi, Chennai, India

autor

Natarajan Yuvaraj

yuvaceg09@gmail.com

Department of Mechanical Engineering, Vel Tech Rangarajan Dr, Sagunthala R&D Institute of Science and Technology, Avadi, Chennai, India

https://orcid.org/0000-0001-6526-4523

autor

Sivalingam Vinothkumar

School of Mechanical Engineering, Shandong University, Jinan, China

autor

Krolczyk Grzegorz

Faculty of Mechanical Engineering, Opole University of Technology, Opole, Poland

autor

Tandon Puneet

Department of Mechanical Engineering, PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, India

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Uwagi

Opracowanie rekordu ze środków MEiN, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2022-2023)

Typ dokumentu

Bibliografia

Identyfikator YADDA

bwmeta1.element.baztech-019d3831-38fd-4d1f-a15f-c97aaa8bfe66