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高温合金水导激光技术瓶颈问题突破路径与研究态势剖析

Analysis of breakthrough paths for bottleneck problems and research trends in water-jet guided laser technology for superalloys

  • 摘要: 水导激光加工技术凭借加工距离长、精度高、热影响区小的优势,已成为加工高温合金气膜孔的有效手段. 然而,当前水导激光技术面临最大功率输出受限与高温合金加工时能量转化效率偏低的双重矛盾,严重制约了该技术的发展.文中系统梳理了水导激光加工高温合金领域的研究进展,重点围绕激光能量在耦合、传输、加工过程中的高效转化机制与工艺合理优化问题展开深入分析与评述. 结果表明,在耦合环节,光源选型、光束整形及耦合准精度对跨介质能量传递效率具有重要影响;传输阶段,激光在水射流中受吸收、散射及热效应影响导致能量损耗,气体辅助与参数调控可改善射流稳定性;加工机理方面,水导激光以等离子体爆炸冲击为主、水射流排屑冷却为辅,形成独特的“冷热交替”去除模式,在复合作用机制下对重熔层厚度、表面形貌及力学性能影响显著;工艺优化方面,单脉冲能量、脉冲频率与扫描路径等参数协同调控对加工质量起关键作用,多步扫描与牺牲层辅助等方法在提升精度方面取得良好效果. 现有研究在单一环节取得阶段性进展,未来应重点解决跨介质能量传递优化、传输损耗抑制及复杂异形件加工能量适配等核心难题.为突破高温合金高质高效水导激光加工技术瓶颈提供理论支撑.

     

    Abstract: Water-jet guided laser machining has emerged as an effective technique for fabricating film cooling holes in superalloys, leveraging its advantages of long processing distance, high precision, and small heat-affected zone. However, the current water-jet guided laser technology faces a dual contradiction of limited maximum power output and low energy conversion efficiency during the processing of superalloys, which severely restricts the development of this technology. The research progress in the field of water-jet guided laser machining of superalloys is systematically reviewed, and the efficient energy conversion mechanisms of laser energy during coupling, transmission, and processing, as well as the reasonable optimization of process parameters, are deeply analyzed and reviewed. The results indicate that in the coupling stage, light source selection, beam shaping, and alignment accuracy have a significant impact on cross-medium energy transfer efficiency. In the transmission stage, the laser undergoes energy loss caused by absorption, scattering, and thermal effects in the water jet, and gas assistance and parameter regulation can improve jet stability. Regarding the processing mechanism, the water-jet guided laser forms a unique “alternating cold and hot” removal mode primarily driven by plasma explosion impact and supplemented by water jet cooling and debris removal, which significantly affects recast layer thickness, surface morphology, and mechanical properties under the synergistic mechanism. In terms of process optimization, the synergistic regulation of parameters such as single pulse energy, pulse frequency, and scanning path plays a key role in machining quality, and methods such as multi-step scanning and sacrificial layer assistance achieve good results in improving precision. Existing studies have made phased progress in individual stages, and future research should focus on solving core challenges such as cross-medium energy transfer optimization, transmission loss suppression, and energy adaptation for processing complex shaped components. This paper provides a theoretical basis for breaking through the bottleneck of high-quality and high-efficiency water-jet guided laser machining technology for superalloys.

     

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