Analysis of the Advantages of Laser Processing of Aerospace Materials Using Diffractive Optics

Serguei P Murzin,Christian Stiglbrunner,Nikolay L Kazanskiy

doi:10.3390/met11060963

Serguei P Murzin, Christian Stiglbrunner + Show 1 more

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https://doi.org/10.3390/met11060963

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Abstract

We considered possibilities of an application of diffractive free-form optics in laser processing of metallic materials in aerospace production. Based on the solution of the inverse problem of heat conduction, an algorithm was developed that calculates the spatial distribution of the power density of laser irradiation in order to create the required thermal effect in materials. It was found that the use of diffractive optics for the laser beam shaping made it possible to obtain specified properties of processed materials. Laser thermal hardening of parts made of chrome–nickel–molybdenum steel was performed. This allowed us to increase the wear resistance due to the creation in the surface layer of a structure that has an increased hardness. In addition, a method of laser annealing of sheet materials from aluminum–magnesium alloy and low-alloy titanium alloys was developed. Application of this method has opened opportunities for expanding the forming options of these materials and for improving the precision in the manufacturing of aircraft engine parts. It was also shown that welding by a pulsed laser beam with a redistribution of power and energy density makes it possible to increase the strength of the welded joint of a heat-resistant nickel-based superalloy. Increasing the adhesion strength of gas turbine engine parts became possible by laser treatment using diffractive free-form optics.

Highlights

Structural materials and components used in the aerospace industry are subjected to extraordinarily harsh conditions during their service life
The presented analysis proves the effectiveness of using diffractive free-form optics in the laser processing of aerospace materials
Based on the solution of the inverse problem of heat conduction, an algorithm was developed that calculates the spatial distribution of the power density of laser irradiation in order to create the required thermal effect in materials

Summary

Introduction

Structural materials and components used in the aerospace industry are subjected to extraordinarily harsh conditions during their service life. These include an extremely wide range of operating temperatures and great mechanical loads. The important characteristics, including durability, ductility, hardness, and toughness, are largely determined by the internal structure of the materials. Control over these characteristics can be exercised by determining the grain size, number and position of lattice defects, impurities, and other substructural units, which requires the appropriate kind and localization of thermal treatment [4,5,6]. The unrivalled and most versatile tool for executing such a treatment is the laser, which is capable of various processing methods and transferring (inducing) precisely defined amounts of energy to confined or hardly accessible regions, all the while avoiding contact and causing vibrations [7,8,9]

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