Abstract: A method for drilling a hole in a component is provided. The method includes directing a confined laser beam of a confined laser drill towards a near wall of the component and sensing a first characteristic of light from the hole in the near wall of the component with a first sensor positioned outside the component. The method also includes sensing a second characteristic of light from the hole in the near wall the component with a second sensor. The second characteristic of light is different from the first characteristic of light. Additionally, the method includes determining a hole progress based on the sensed first characteristic of light and the sensed second characteristic of light.

Abstract: This disclosure provides a system, method, and resulting workpiece combining liquid guided laser and electrical discharge machining to create a common feature. The workpiece is positioned in a liquid guided laser cutting path and machined by the liquid guided laser device to create an intermediate feature in the workpiece. The work piece is then positioned in an electrical discharge machining (EDM) device so that an electrode of the EDM device is operatively positioned proximate the intermediate feature and machined using the EDM device to modify the intermediate feature in the workpiece to create the finished common feature in the workpiece.

Abstract: When water jet guided laser drilled through the first body, there is a confined embodiment between the first body and the second body. To prevent water jet guided laser to continue in this direction and create damage on the second body, a volume vibrator is connected to the embodiment and media that filled embodiment get pumped in and pumped out from the embodiment at adjustable frequency and cycle volume. Mechanical energy is then transferred into the embodiment to generate local media vibration. The laminar flowing state of the water jet is interrupted and the laser beam confined in the water jet is dispersed. Plugging method is also involved to insure when there are multiple holes on the embodiment, there will be enough mechanical energy get transferred to the laser breakthrough location.

Abstract: A method for drilling a hole in a component is provided. The method includes directing a confined laser beam of the confined laser drill towards a near wall of the component and sensing a characteristic of light directed along a beam axis of the confined laser beam away from the component with a sensor. The method also includes determining one or more operational conditions based on the characteristic of the light sensed with the sensor. The one or more operational conditions includes at least one of a depth of the hole being drilled by the confined laser drill and a material into which the confined laser beam of the confined laser drill is being directed. Such a method may allow for more appropriate control of the confined laser drill.

Abstract: A computer aided technology system includes a processor. The processor may receive a design model for a blade that has multiple diffuser holes. Also, the processor may derive a hole position and a vector for each of the multiple diffuser holes. In addition, the processor may translate the hole position to a machine coordinate system to create a translated hole position. Moreover, the processor may generate a manufacturing program based on the translated hole position and the vector. The blade includes a stator vane, a rotor vane, or a combination thereof. Further, the blade is included in a compressor, a gas turbine engine, or a combination thereof.

Abstract: This disclosure provides a shield for use in a liquid guided laser system and related method of use. The shield comprises a rigid body with a target facing surface. The rigid body defines a through hole with a diameter that accommodates a liquid guided laser path. The rigid body has a thickness that defines a length of the liquid guided laser path through the rigid body. The thickness of the rigid body is at least twice the diameter of the through hole. The rigid body is positioned in the liquid guided laser path of the liquid guided laser system between a discharge nozzle of the liquid guided laser system and a target.

Abstract: When water jet guided laser drilled through the first body, there is a confined embodiment between the first body and the second body. To prevent water jet guided laser to continue in this direction and create damage on the second body, a volume vibrator is connected to the embodiment and media that filled embodiment get pumped in and pumped out from the embodiment at adjustable frequency and cycle volume. Mechanical energy is then transferred into the embodiment to generate local media vibration. The laminar flowing state of the water jet is interrupted and the laser beam confined in the water jet is dispersed. Plugging method is also involved to insure when there are multiple holes on the embodiment, there will be enough mechanical energy get transferred to the laser breakthrough location.

Abstract: Based on the mechanism of the water jet guided laser system, both shielding gas and optical to water jet coupling components have significant influence on the laminar flowing state of the water jet. By applying a camera and imaging system to monitor the laser jet and analyze the width comparing to pre-measured and stored data, we can draw a conclusion on health of optical to water jet coupling components as well as the machining progress of the laser beam. A clear system definition and procedure have been defined to understand and implement this invention.

Abstract: A head assembly for a liquid jet guided laser system is disclosed having a coupling unit removably disposed to a laser focus optic module of the laser system. The coupling unit has a nozzle assembly removably connected to the coupling unit. The nozzle assembly has a liquid jet nozzle and a nozzle cap. The nozzle cap has a plurality of axial assist gas conduits and static assist gas conduits in fluid communication with an assist gas source extending through the nozzle cap body to individually transport assist gas to axial exit ports and static exit ports positioned to exhaust assist gas proximate the liquid jet. At least a portion of the plurality of axial assist gas conduits are partitioned from fluid communication with the liquid jet hole. A lateral movement assembly can be configured between the laser focus optic module and coupling unit.

Abstract: A system includes a processor configured to receive a design model for a blade that has multiple diffuser holes. The processor is also configured to generate multiple points along an edge of each of the multiple diffuser holes. Further, the processor is configured to generate multiple vectors and each of the multiple points includes a corresponding vector. Moreover, each of the multiple vectors originates at the corresponding vector's corresponding point. Further, the processor is configured to apply the multiple vectors to inspect one or more manufactured diffuser holes.

Abstract: A system includes a processor configured to receive a design model for a blade that has multiple diffuser holes. The processor is also configured to generate multiple points along an edge of each of the multiple diffuser holes. Further, the processor is configured to generate multiple vectors and each of the multiple points includes a corresponding vector. Moreover, each of the multiple vectors originates at the corresponding vector's corresponding point. Further, the processor is configured to apply the multiple vectors to inspect one or more manufactured diffuser holes.

Abstract: A computer aided technology system includes a processor. The processor may receive a design model for a blade that has multiple diffuser holes. Also, the processor may derive a hole position and a vector for each of the multiple diffuser holes. In addition, the processor may translate the hole position to a machine coordinate system to create a translated hole position. Moreover, the processor may generate a manufacturing program based on the translated hole position and the vector. The blade includes a stator vane, a rotor vane, or a combination thereof. Further, the blade is included in a compressor, a gas turbine engine, or a combination thereof.

Abstract: A method of monitoring an operation status of a confined laser cutting tool includes emitting light in the form of laser beams from a laser source. The method includes using a nozzle to form a confining column composed of a liquid. The method further includes forming a confined laser beam, the confined laser beam defined by the confluence of the laser beams and the confining column. The method also includes sensing a characteristic of the confined laser beam with a sensor. The method further includes determining the operation status of the confined laser cutting tool based on the sensed characteristic of the confined laser beam. The method also includes deactivating the laser source when the sensed characteristic of the confined laser beam reaches a predetermined threshold. The method may also include providing an operator notification after deactivating the laser source.

Abstract: A method of monitoring an operation status of a confined laser cutting tool includes emitting light in the form of laser beams from a laser source. The method includes using a nozzle to form a confining column composed of a liquid. The method further includes forming a confined laser beam, the confined laser beam defined by the confluence of the laser beams and the confining column. The method also includes sensing a characteristic of the confined laser beam with a sensor. The method further includes determining the operation status of the confined laser cutting tool based on the sensed characteristic of the confined laser beam. The method also includes deactivating the laser source when the sensed characteristic of the confined laser beam reaches a predetermined threshold. The method may also include providing an operator notification after deactivating the laser source.

Abstract: A method for repairing one or more holes in a near wall of a component is provided. The method includes determining updated hole information, including an updated location, of a first hole in the near wall of the component. The method also includes directing a confined laser beam of the confined laser drill towards the near wall of the component at the updated location of the first hole to drill through a coating of the component extending over and/or positioned in the first hole. The method also includes sensing a characteristic of light reflected from the updated location of the first hole and determining the confined laser beam of the confined laser drill has drilled through a portion of the coating of the component extending over and/or positioned in the first hole based on the sensed characteristic of light.

Abstract: This disclosure provides a system, method, and resulting workpiece combining liquid guided laser and electrical discharge machining to create a common feature. The workpiece is positioned in a liquid guided laser cutting path and machined by the liquid guided laser device to create an intermediate feature in the workpiece. The work piece is then positioned in an electrical discharge machining (EDM) device so that an electrode of the EDM device is operatively positioned proximate the intermediate feature and machined using the EDM device to modify the intermediate feature in the workpiece to create the finished common feature in the workpiece.

Abstract: A method for cutting passages in an airfoil using a liquid-jet guided laser beam includes positioning a frustoconical tip of the liquid-jet guided laser at a first X, Y and Z location that is defined with respect to the airfoil and at a first standoff distance of greater than 5 mm and less than 20 mm from an outer surface of the airfoil. The method also includes generating a laser beam confined within a fluid column via the liquid jet guided laser, wherein the laser beam is aimed at the outer surface. The method further includes monitoring for breakthrough of the laser beam through an inner surface of an inner cavity of the airfoil, shutting off the laser beam once breakthrough is detected and repositioning the frustoconical tip at a second X, Y and Z location and at a second standoff distance. A system for cutting a passage in an airfoil is also disclosed herein.

Abstract: A system for forming a cooling hole in an airfoil includes a liquid-jet guided laser. The liquid-jet guided laser generates a laser beam confined within a fluid column. The fluid column/laser beam is directed at an outer surface of the airfoil. The system also includes a purge medium supply that is fluidly coupled to an aperture of the airfoil. The purge medium supply provides a purge medium into an inner cavity of the airfoil. The purge medium flow is oriented to flow in a flow direction that is substantially parallel to an inner surface of the cavity. A cooling hole is formed in the airfoil and extends through the outer surface and penetrates the inner surface of the cavity. A centerline of the cooling hole forms an acute angle with respect to the purge medium flow direction. The system described herein provides a method for manufacturing an airfoil.

Abstract: This disclosure provides a shield for use in a liquid guided laser system and related method of use. The shield comprises a rigid body with a target facing surface. The rigid body defines a through hole with a diameter that accommodates a liquid guided laser path. The rigid body has a thickness that defines a length of the liquid guided laser path through the rigid body. The thickness of the rigid body is at least twice the diameter of the through hole. The rigid body is positioned in the liquid guided laser path of the liquid guided laser system between a discharge nozzle of the liquid guided laser system and a target.

Abstract: A head assembly for a liquid jet guided laser system is disclosed having a coupling unit removably disposed to a laser focus optic module of the laser system. The coupling unit has a nozzle assembly removably connected to the coupling unit. The nozzle assembly has a liquid jet nozzle and a nozzle cap. The nozzle cap has a plurality of axial assist gas conduits and static assist gas conduits in fluid communication with an assist gas source extending through the nozzle cap body to individually transport assist gas to axial exit ports and static exit ports positioned to exhaust assist gas proximate the liquid jet. At least a portion of the plurality of axial assist gas conduits are partitioned from fluid communication with the liquid jet hole. A lateral movement assembly can be configured between the laser focus optic module and coupling unit.