Abstract: A method for detecting drilling progress in laser drilling is provided. The method includes sensing a process condition during the drilling of an airfoil, and sensing a change in the process condition indicative of a breakthrough of a laser from the laser drill through a near wall of the airfoil. The method additionally includes continuing to sense the process condition subsequent to the sensed change in the process condition to improve the accuracy of the breakthrough detection.

Abstract: A method for manufacturing an airfoil is provided, the method including drilling a hole in a near wall of the airfoil using a laser drill and activating a back strike protection in a cavity of the airfoil. The method additionally includes detecting a breakthrough of a laser from the laser drill through the near wall of the airfoil and subsequently initiating a drilling subroutine, with the drilling subroutine including a continued operation of the laser drill. Such a method may provide for an improved hole, such as a cooling passage, in the airfoil.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.

Abstract: A gas turbomachine nozzle includes a base portion having a first fluid inlet and a second fluid inlet, and an outlet portion having one or more outlets. A connection section fluidically connects the base portion and the outlet portion. An orifice plug is arranged in the base portion at the second fluid inlet. The orifice plug includes one or more openings fluidically connecting the second fluid inlet and the connection section.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation on a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the preliminary wax casting model; coating the modified wax model to form a mold shape around the modified wax model; removing the modified wax model to leave a casting mold including the at least one additional feature; forming a shape from a casting material using the casting mold having the at least one additional feature; and scanning the modified wax model to image the at least one additional feature after the performing of the laser ablation.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole.

Abstract: A system and method for additive manufacturing an object using multiple lasers is disclosed herein. The system includes a first laser generating a first focused laser beam having a first surface area where the first focused laser beam is directed onto a first quantity of a powder material on a substrate so as to fuse particles of the powder material in a first layer of the substrate. A second laser generating a second focused laser beam having a second surface area where the second laser beam is directed onto a second quantity of the powder material on the substrate so as to fuse particles of the powder material in the first layer of the substrate. The first surface area of the first focused laser beam is greater than the second surface area of the second focused laser beam.

Abstract: The present disclosure provides a method for determining a hole completing in laser drilling of a hole in a near wall of an airfoil. The method includes drilling a hole in the near wall of the airfoil using a laser drill. The laser drill may move in a pattern relative to the airfoil. The method also includes determining when the drilling of the hole is complete based on a calculated time duration between successive breakthroughs of a laser from the laser drill through the near wall of the airfoil, or based on a calculated time duration since the latest breakthrough of the laser from the laser drill through the near wall of the airfoil.

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 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: 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: A method for manufacturing an airfoil includes confining an unfocused laser beam inside a first fluid column to create a confined laser beam, directing the confined laser beam at a surface of the airfoil, and penetrating the surface of the airfoil with the confined laser beam. The method further includes detecting penetration of the confined laser beam through the surface of the airfoil via an optical sensor disposed within a cavity defined within the airfoil.

Abstract: A system for forming a passage in an airfoil includes a liquid-jet guided laser that generates a laser beam confined within a fluid column, and a purge medium supply that is fluidly coupled to an aperture of the airfoil. A purge medium flows from the purge medium supply in a flow direction that is substantially parallel to an inner surface of the inner cavity. A controller is configured to direct the liquid-jet guided laser to cut a first passage through the outer surface. A centerline of the passage forms an acute angle with respect to the purge medium flow direction. The first passage is formed at a first radial position that is radially distal to the aperture. A method for forming passages in an airfoil using the system described herein is also disclosed.

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: 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 first hole position on a near wall of the component. The method also includes sensing a characteristic of light within a cavity defined by the component. The near wall is positioned adjacent to the cavity and the sensor is positioned outside the cavity. The method also includes determining a first breakthrough of the confined laser beam through the near wall the component at the first hole position based on the light from within the cavity sensed with the sensor. Such a method may allow for more convenient and time efficient confined laser drilling of gas turbine components.

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 method for drilling a hole in a component is provided. The method includes positioning a confined laser drill within a predetermined distance of a near wall of the component for directing a confined laser beam of the confined laser drill towards an outside surface of the near wall. The confined laser beam is formed of a liquid column and a laser positioned within the liquid column. The method also includes sensing an amount of liquid from the confined laser beam present outside the near wall of the component with a sensor. Moreover, the method includes determining a breakthrough the confined laser beam through the near wall based on the amount of liquid sensed outside the near wall of the component.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation on a preliminary wax casting model to form a modified wax model including at least one additional feature absent from the preliminary wax casting model; coating the modified wax model to form a mold shape around the modified wax model; removing the modified wax model to leave a casting mold including the at least one additional feature; forming a shape from a casting material using the casting mold having the at least one additional feature; and scanning the modified wax model to image the at least one additional feature after the performing of the laser ablation.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.

Abstract: Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one cooling hole absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one cooling hole.