High Speed CMC Laser Machining

Physical Sciences Inc. (PSI) proposes to develop a high speed laser machining process for ceramic matrix composites. The recent development of high rate, high pulse power lasers and the non-contact nature of the PSI process minimize the damage typical of other laser machining processes. It also enables precise placement of through holes, trenches and identification markings. The goal of the Phase I SBIR is to demonstrate the feasibility of a high speed, low cost laser machining process for ceramic matrix composites that . 1) Can machine features in CMCs with high precision. 2) Leaves a machined surface with a surface roughness less than 5 microns. 3) Increases finishing tool life by 100 times. 4) Does not degrade the mechanical strength of the machined part. 5) Can be scaled-up to cut component machining in half. During the Phase I project we will demonstrate the feasibility of the laser machining process by machining holes, countersunk holes and grooves in ceramic matrix composite panels. We will show that the minimal damage induced in the CMC enables the mechanical strength of the material in the machined component to be the same as that of the as fabricated composite. BENEFITS: The development of a high speed laser machining process for ceramic matrix composites will accelerate the use of CMCs in aerospace systems. The low cost, high speed laser machining process will reduce the overall cost of complex CMC components and make CMCs competitive with nickel superalloys in turbine engine systems.