SpringerLink
Log in

Insights into drilling film cooling holes on ceramic-coated nickel-based superalloys

  • Review Article
  • Published:
Archives of Civil and Mechanical Engineering Aims and scope Submit manuscript

Abstract

This article aims at providing insights into various drilling operations relating to the production of holes of small diameter for film cooling, particularly inclined holes, in aero-engine turbine blades, made of Yttria-stabilized Zirconia (YSZ) coated superalloy. Drilling inclined holes on YSZ coated superalloys that find use in aerospace industries is difficult due to the presence of two sections of materials, each section possessing different material properties. This article indicates five machining processes, namely conventional drilling, electrical discharge drilling, laser drilling, electro chemical discharge machining (ECDM), and abrasive water jet machining (AWJM). Machinability and the challenges involved in the fabrication of micro straight and inclined holes on ceramic-coated nickel-based superalloys have been discussed. Previous researchers have attempted at drilling tiny holes (≤ 2 mm) on ceramic-coated and uncoated nickel-based superalloys at different hole angles varying from 10° to 90°. Material removal was seen as difficult to control in the YSZ coated section when compared to the superalloys. Despite the occurrence of a controlled manner of material removal in different machining techniques, the holes produced had poor geometry and surface finish with cavities on the ceramic coat and burr formation at the hole exit. There was also the problem of thermal spalling, delamination, flakes, spatters, recast layer and cracks seen over the ceramic coat due to the employment of thermal-based machining techniques including laser drilling with advanced pulse settings. Kee** this in view, the AWJM technique is found to be a good alternative technique for drilling inclined holes with size constraints as the cold process maintains material integrity, followed by the ECDM and the conventional drilling processes. However, the hybrid process, namely ECDM, has still been a complex phenomenon in the material removal mechanism of the YSZ coated section consuming a lot of time. Based on the key results from the different setups, the outcome of this work provides a platform for scientists and engineers working in aerospace industries for finding a suitable machining process for drilling precision holes on the YSZ coated nickel-based superalloys.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig.1
Fig.2
Fig.3
Fig.4
Fig.5
Fig.6
Fig.7
Fig.8
Fig.9
Fig.10
Fig.11
Fig.12
Fig.13
Fig.14
Fig.15
Fig.16
Fig.17
Fig.18
Fig. 19
Fig. 20
Fig.21
Fig.22
Fig. 23
Fig.24
Fig.25
Fig.26
Fig.27
Fig.28
Fig.29
Fig.30
Fig.31
Fig.32
Fig.33
Fig.34
Fig. 35
Fig.36
Fig.37
Fig.38
Fig.39
Fig.40
Fig.41
Fig.42
Fig.43
Fig.44
Fig.45
Fig.46
Fig.47
Fig.48

Similar content being viewed by others

Abbreviations

APS:

Air plasma spray

AWJM:

Abrasive water jet machining

BC:

Bond coat

ECM:

Electro chemical machining

EB-PVD:

Electron beam physical vapour deposition

ECDM:

Electro chemical discharge machining

EDD/M:

Electrical discharge drilling/machining

HAZ:

Heat affected zone

HVOF:

High-velocity oxygen fuel

LD:

Laser drilling

MRR:

Material removal rate

SEM:

Scanning electron microscope

TBC:

Thermal barrier coating

YSZ:

Yttria-stabilized zirconia

References

  1. Avci A, Eker AA, Eker B. Microstructure and oxidation behavior of atmospheric plasma-sprayed thermal barrier coatings. In: Exergetic. Energetic and Environmental Dimensions: Elsevier; 2018. p. 793–814.

    Google Scholar 

  2. Okura T. Materials for aircraft engines, aircraft propulsion ASEN 5063. USA: University of Colorado Boulder; 2015.

    Google Scholar 

  3. Teng S, Han J-C, Poinsatte PE. Effect of film-hole shape on turbine-blade film-cooling performance. J Thermophys Heat Transfer. 2001;15:257–65.

    Article  CAS  Google Scholar 

  4. Mohammadi-Ahmar A, Solati A, Ghasemi J. Numerical analysis on the film cooling of leading edge with laid back holes to determine the optimal angle for the holes. Aust J Mech Eng. 2020;18:429–41.

    Article  Google Scholar 

  5. Svetlana K. Application and improvement of gas turbine blades film cooling. In: International Conference on Aerospace System Science and Engineering. New York: Springer; 2018. p. 69–91.

    Google Scholar 

  6. Kannan S, Pervaiz S, Ghoshal, A. "An experimental investigation of inclined hole drilling for cfrp under various lubrication techniques." In: Proceedings of the ASME 2018 International Mechanical Engineering Congress and Exposition. Volume 2: Advanced Manufacturing. Pittsburgh, Pennsylvania, USA. November 9–15, 2018. V002T02A011. ASME.

  7. Kwong J, Axinte D, Withers P. The sensitivity of Ni-based superalloy to hole making operations: Influence of process parameters on subsurface damage and residual stress. J Mater Process Technol. 2009;209:3968–77.

    Article  CAS  Google Scholar 

  8. Azim S, Gangopadhyay S, Mahapatra SS, Mittal RK, Singh A, Singh RK. Study of cutting forces and surface integrity in micro drilling of a Ni-based superalloy. J Manuf Process. 2019;45:368–78.

    Article  Google Scholar 

  9. Khadtare AN, Pawade RS, Joshi S. Surface integrity studies for straight and inclined hole in micro-drilling of thermal barrier coated Inconel 718: a turbine blade application. Precis Eng. 2020;66:166–79.

    Article  Google Scholar 

  10. Zhou Y, Li H, Ma L, Chen J, Tan Y, Yin G. Study on hole quality and surface quality of micro-drilling nickel-based single-crystal superalloy. J Braz Soc Mech Sci Eng. 2020;42:1–13.

    Article  Google Scholar 

  11. Zhang G, Guo Y, Wang L. Experimental study on the machining of inclined holes for thermal barrier-coated nickel superalloys by EDM. J Mater Eng Perform. 2016;25:4574–80.

    Article  CAS  Google Scholar 

  12. Gao C, Liu Z, **e T, Guo C. Influence of electrical discharge machining on thermal barrier coating in a two-step drilling of nickel-based superalloy. Arab J Sci Eng. 2021;46:2009–20.

    Article  CAS  Google Scholar 

  13. Guo Y, Zhang G, Wang L, Hu Y. Optimization of parameters for EDM drilling of thermal-barrier-coated nickel superalloys using grey relational analysis method. Int J Adv Manuf Technol. 2016;83:1595–605.

    Article  Google Scholar 

  14. Kliuev M, Boccadoro M, Perez R, Dal Bó W, Stirnimann J, Kuster F, Wegener K. EDM drilling and sha** of cooling holes in Inconel 718 turbine blades. Procedia CIRP. 2016;42:322–7.

    Article  Google Scholar 

  15. Manimaran S, Dhas AAG, Joy N, Raja KS, Saikia K, Kumar S. Analysis of surface texture of Ni-based super alloy with thermal barrier coating system (TBC) for gas turbine blade. In: AIP Conference Proceedings, 2020. AIP Publishing LLC, pp. 090023.

  16. Zhang Y, Xu Z, Zhu D, Qu N, Zhu Y. Drilling of film cooling holes by a EDM/ECM in situ combined process using internal and side flushing of tubular electrode. Int J Adv Manuf Technol. 2016;83:505–17.

    Article  Google Scholar 

  17. Horn A, Weichenhain R, Albrecht S, Kreutz EW, Michel J, Niessen M, Kostrykin V, Schulz W, Etzkorn A, Bobzin K Microholes in zirconia-coated Ni-superalloys for transpiration cooling of turbine blades. In: High-Power Laser Ablation III; 2000. International Society for Optics and Photonics, pp. 218–226.

  18. Zheng C, Zhao K, Shen H, Zhao X, Yao Z. Crack behavior in ultrafast laser drilling of thermal barrier coated nickel superalloy. J Mater Process Technol. 2020;282(116678): 116678.

    Article  CAS  Google Scholar 

  19. Marimuthu S, Smith B, Kiely A, Liu Y. Delamination-free millisecond laser drilling of thermal barrier coated aerospace alloys. J Laser Appl. 2019;31: 042001.

    Article  Google Scholar 

  20. Marimuthu S, Smith B. Water-jet guided laser drilling of thermal barrier coated aerospace alloy. Int J Adv Manuf Technol. 2021;113(1–2):177–91. https://doi.org/10.1007/s00170-020-06584-0.

    Article  Google Scholar 

  21. Das DK, Pollock TM. Femtosecond laser machining of cooling holes in thermal barrier coated CMSX4 superalloy. J Mater Process Technol. 2009;209:5661–8.

    Article  CAS  Google Scholar 

  22. Beck T. Laser drilling in gas turbine blades: sha** of holes in ceramic and metallic coatings. Wiley Online Library, New York; 2011.

  23. Parthiban K, Duraiselvam M, Manivannan R. TOPSIS based parametric optimization of laser micro-drilling of TBC coated nickel based superalloy. Opt Laser Technol. 2018;102:32–9.

    Article  ADS  CAS  Google Scholar 

  24. Wang R, Wang K, Dong X, Fan Z, Duan W, Mei X, Wang W, Cui J, Zhang S. An experimental investigation into the defects of laser-drilled holes in thermal barrier coated Inconel 718 superalloys. Int J Adv Manuf Technol. 2018;96:1467–81.

    Article  Google Scholar 

  25. Wang R, Dong X, Wang K, Sun X, Fan Z, Duan W. Investigation on millijoule femtosecond laser spiral drilling of micro-deep holes in thermal barrier coated alloys. Int J Adv Manuf Technol. 2021;114(3–4):857–69. https://doi.org/10.1007/s00170-021-06901-1.

    Article  Google Scholar 

  26. Sun X, Dong X, Wang K, Wang R, Fan Z, Duan W. Experimental investigation on thermal effects in picosecond laser drilling of thermal barrier coated In718. Opt Laser Technol. 2019;113:150–8.

    Article  ADS  CAS  Google Scholar 

  27. Lu C, Duan W, Wang K, Wang R, Tang Z. Experiments of drilling micro-holes on superalloy with thermal barrier coatings by using femtosecond laser. Ferroelectrics. 2020;564:37–51.

    Article  ADS  CAS  Google Scholar 

  28. Kamalu J, Byrd P, Pitman A. Variable angle laser drilling of thermal barrier coated nimonic. J Mater Process Technol. 2002;122:355–62.

    Article  CAS  Google Scholar 

  29. Forget P, Jeandin M, Lechervy P, Varela D. Laser drilling of a superalloy coated with ceramic. Superalloys. 1988;1988:553–62.

    Google Scholar 

  30. Girardot J, Schneider M, Berthe L, Favier V. Investigation of delamination mechanisms during a laser drilling on a cobalt-base superalloy. J Mater Process Technol. 2013;213:1682–91.

    Article  CAS  Google Scholar 

  31. Voisey K, Thompson J, Clyne T. Damage caused during laser drilling of thermal spray TBCs on superalloy substrates. In: International Congress on Applications of Lasers & Electro-Optics. Laser Institute of America; 2001, pp 257–265.

  32. Sezer H, Li L, Schmidt M, Pinkerton A, Anderson B, Williams P. Effect of beam angle on HAZ, recast and oxide layer characteristics in laser drilling of TBC nickel superalloys. Int J Mach Tools Manuf. 2006;46:1972–82.

    Article  Google Scholar 

  33. Hernandez-Castaneda J, Chi W, Yongwei F, Lan N, Khin M, Hongyu Z. Investigation on high power laser removal of thermal barrier coating (TBC) and bond layer (MCrAlY) from Inconel 718 alloy. Int J Peening Sci Technol. 2019;1:201–19.

    Google Scholar 

  34. Voisey K, Clyne T. Laser drilling of cooling holes through plasma sprayed thermal barrier coatings. Surf Coat Technol. 2004;176:296–306.

    Article  CAS  Google Scholar 

  35. Sezer H, Pinkerton AJ, Li L, Byrd P. An investigation into delamination mechanisms in inclined laser drilling of thermal barrier coated aerospace superalloys. J Laser Appl. 2005;17:225–34.

    Article  Google Scholar 

  36. Fan Z, Dong X, Wang K, Duan W, Wang R, Mei X, Wang W, Cui J, Yuan X, Xu C. Effect of drilling allowance on TBC delamination, spatter and re-melted cracks characteristics in laser drilling of TBC coated superalloys. Int J Mach Tools Manuf. 2016;106:1–10.

    Article  Google Scholar 

  37. Sezer H, Li L. Mechanisms of acute angle laser drilling induced thermal barrier coating delamination. J Manuf Sci Eng. 2009;131(5):051014.

    Article  Google Scholar 

  38. Kang X, Tang W. Micro-drilling in ceramic-coated Ni-superalloy by electrochemical discharge machining. J Mater Process Technol. 2018;255:656–64.

    Article  CAS  Google Scholar 

  39. Zhang Y, Xu Z, Zhu Y, Zhu D. Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling. Chin J Aeronaut. 2016;29:560–70.

    Article  Google Scholar 

  40. Tang W, Kang X, Zhao W, Qian J, Lauwers B. Discharge characteristics in electrochemical discharge machining of ceramic-coated Ni-superalloy. Procedia CIRP. 2020;95:737–42. https://doi.org/10.1016/j.procir.2020.02.307.

    Article  Google Scholar 

  41. Tarlochan S, Akshay D. Fabrication of micro holes in Yttria-stabilized zirconia (Y-SZ) by hybrid process of electrochemical discharge machining (ECDM). Ceram Int. 2021;47(16):23677–81.

    Article  Google Scholar 

  42. Yusen H, Zhengyang X, Feng W, Chenxiang Z. Electrochemical discharge drilling of inclined micro holes with step feeding method. Int J Electrochem Sci. 2020;15:2713–26.

    Article  Google Scholar 

  43. Hashish M. Abrasive-waterjet drilling of high temperature jet engine parts. In: ASME Pressure Vessels and Pi** Conference, 2009; pp. 65–73.

  44. Yuvaraj N, Arunkumar N, Nivetha M, Esther AL. Abrasive water jet piercing of inclined holes on ceramic coated nickel superalloy: a preliminary study. Manuf Lett. 2020;26:59–63.

    Article  Google Scholar 

  45. Liu H-T. Hole drilling with abrasive fluidjets. Int J Adv Manuf Technol. 2007;32:942–57.

    Article  Google Scholar 

  46. Hlavacek P, Zlamal T, Sitek L. Abrasive water jet drilling of cooling holes in aeroengines: preliminary experimental study. MM Sci J. 2018; 2218–2232.

  47. Zhao K, Gao C, Liu Z, Guo C. Investigation of removing thermal barrier coatings from Nickel based super-alloy using abrasive water jet. In: IOP Conference Series: Materials Science and Engineering, IOP Publishing; 2018. pp. 022112.

  48. Gao C, Liu Z, Zhao K, Guo C. Abrasive water jet drilling of ceramic thermal barrier coatings. Procedia CIRP. 2018;68:517–22.

    Article  Google Scholar 

  49. Balaji V, Yuvaraj N. Abrasive water jet piercing of straight and inclined holes on Yttria-stabilized zirconia coated Ni-based superalloy. Mater Manuf Processes. 2022;37:1175–89.

    Article  CAS  Google Scholar 

  50. Khadtare A, Pawade R, Varghese A, Joshi S. Micro-drilling of straight and inclined holes on thermal barrier coated Inconel 718 for turbine blade cooling. Mater Manuf Processes. 2020;35(7):783–96.

    Article  CAS  Google Scholar 

  51. Zhang P, Guo XY, Zhang DY. Step vibration drilling for micro inclined hole. Adv Mater Res. 2011;199–200:1857–60.

    Article  Google Scholar 

  52. Zhang P, Guo XY, Wu CG. Research of micro hole vibration drilling process and experiment. Mater Sci Forum. 2011;697–698:161–5.

    Article  Google Scholar 

  53. Li Z, Wei X, Guo Y, Sealy MP. State-of-art, challenges, and outlook on manufacturing of cooling holes for turbine blades. Mach Sci Technol. 2015;19:361–99.

    Article  CAS  Google Scholar 

  54. Zheng N, **a K, Yang H, Gao F, Song S. Water-assisted femtosecond laser drilling of alumina ceramics. Ceram Int. 2021;47(8):11465–73.

    Article  Google Scholar 

  55. Rahman M, Wong Y, Nguyen M. Compound and hybrid micromachining: Part II–hybrid micro-EDM and micro-ECM. Compr Mater Process. 2014;11:113–50.

    Article  Google Scholar 

  56. Natarajan Y, Murugesan PK, Mohan M, Khan SALA. Abrasive water jet machining process: a state of art of review. J Manuf Process. 2020;49:271–322.

    Article  Google Scholar 

  57. Yuvaraj N, Shamli CS, Mughilvalavan M, Muruganandhan R. Abrasive water jet piercing of superalloys: a study of small diameter deep holes. In: Advances in manufacturing engineering and materials II: Proceedings of the International Conference on Manufacturing Engineering and Materials (ICMEM 2020), 21–25 June, Nový Smokovec, Slovakia, Springer; 2021. pp. 183–196.

  58. Klocke F, Klink A, Veselovac D, Aspinwall DK, Soo SL, Schmidt M, Schilp J, Levy G, Kruth J-P. Turbomachinery component manufacture by application of electrochemical, electro-physical and photonic processes. CIRP Ann. 2014;63:703–26.

    Article  Google Scholar 

  59. Klocke F, Schmitt R, Zeis M, Heidemanns L, Heinen D, Klink A. Technological and economical assessment of alternative process chains for blisk manufacture. Procedia CIRP. 2015;35:67–72.

    Article  Google Scholar 

Download references

Funding

This study received no funding.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Vel Tech Rangarajan Dr, Sagunthala R&D Institute of Science and Technology, Avadi, Chennai, India

    Balaji Vasudevan & Yuvaraj Natarajan

  2. School of Mechanical Engineering, Shandong University, **an, China

    Vinothkumar Sivalingam

  3. Faculty of Mechanical Engineering, Opole University of Technology, Opole, Poland

    Grzegorz Krolczyk

  4. Department of Mechanical Engineering, PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, India

    Puneet Tandon

Authors
  1. Balaji Vasudevan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuvaraj Natarajan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Vinothkumar Sivalingam
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Grzegorz Krolczyk
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Puneet Tandon
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yuvaraj Natarajan.

Ethics declarations

Conflict of interest

Authors declare that there is no conflict of interest.

Ethical approval

This article does not contain any studies with human participants or animals performed by any of the authors. This study was done according to ethical standards.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Vasudevan, B., Natarajan, Y., Sivalingam, V. et al. Insights into drilling film cooling holes on ceramic-coated nickel-based superalloys. Archiv.Civ.Mech.Eng 22, 141 (2022). https://doi.org/10.1007/s43452-022-00465-x

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s43452-022-00465-x

Keywords

Search

Navigation