Air film cooling structure is an important factor to improve the cooling performance of aero-engine turbine blades. In order to realize high-efficiency and high-quality machining of turbine blade air film holes, a new method of water jet-guided laser (WJGL) machining based on double staggered-axis auxiliary gases is proposed. On the basis of the currently commonly used helium coaxial auxiliary jet, an external staggered axis argon auxiliary jet is added. The external staggered-axis gas jet can blow away the exiting liquid close to the water jet while improving the gas protection range. The simulation results verify the blowing away effect of the outer staggered-axis assisted gas jet on the outwardly discharged liquid. The experimental results show that, in terms of processing efficiency, the double staggered-axis gas-assisted WJGL technology improves 35.1 % and 15.6 % higher compared with the single-axis gas-assisted and double coaxial gas-assisted methods, respectively. In terms of processing quality, the double staggered-axis gas-assisted WJGL technology processes the inner wall surface of the micro-hole with less taper and roughness, and the processing consistency is better. The double staggered-axis gas-assisted WJGL technology with a laser power of 40 W and an external staggered-axis angle of 35° was applied to process holes with a depth of 4 mm and a diameter of 0.8 mm in a nickel-based high-temperature alloy. The average penetration time of the holes was 152 s, the wall roughness Ra was less than 0.4 μm, and the thickness of the heat-affected zone was less than 1 μm.
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