Laser-Beam Drilling of a Jet-Engine Nozzle

Approximately 74,000 holes with a diameter of 1.5 mm shall be drilled into the primary nozzle of a jet engine by using laser radiation. The drilling technique trepanning is used. The nozzle has a diameter of about 900 mm and a length of about 350 mm. The holes will be drilled distributed into 2048 rows, each with 36 holes around the circumference of the nozzle. The nozzle with a material thickness of 1.5 mm is made of titanium alloy Ti 6-2-4-2.

Strategies for Drilling with Laser Beams

Depending on the component thickness and the required quality (precision) and productivity (drilling time), holes with diameters from 1 µm up to several millimeters can be achieved by using single-pulse drilling, percussion drilling, trepanning or helical drilling. The single pulse drilling can be performed "on-the-fly", so that up to 300 holes per second with a diameter of e.g. 60 microns in 1 mm thick material can be achieved. Larger hole depths can be achieved by using percussion drilling. For hole diameters larger than 300 microns, trepanning is used where a relative movement between the workpiece and laser radiation occurs. Holes with high precision concerning geometry and high metallurgical quality are achieved by using helical drilling.

3D-component without support structures, manufactured with Laser Metal Deposition (LMD)

In this demonstration, laser cladding, also known as Laser Metal Deposition (LMD), is used to additively manufacture a three-dimensional part without support structures. Off-line programming is used to generate the program for the robot system at Fraunhofer ILT. Inconel 625, a nickel-based super-alloy, is used as additive material. This material is often used in the turbine and chemical sector. A continuous coaxial powder nozzle from Fraunhofer ILT is used. Total process time is 23 minutes. For further information please visit our website:

Aachen Centre for Integrative Lightweight Production

With its partner institutes active in various fields of lightweight production technology (750 scientists and 1,100 graduate assistants) on the RWTH Aachen Campus, AZL regroups all the required know-how to help the composites industry develop tomorrow’s lightweight production technology. The institutes’ knowledge covers the fields of textiles (ITA), plastics and composite materials (IKV), production technology (WZL, ISF, Fraunhofer IPT and Fraunhofer ILT), quality assurance and production-integrated measurement technology (WZL), lightweight design (SLA) and automotive production (IKA).

Artificial Vascular Systems - ArtiVasc 3D - on the way to bio-artificial tissue

New CAM system for efficient laser material deposition

The Fraunhofer Institute for Laser Technology ILT has developed an offline programming system for laser material deposition. The LMD Cam3D program enables process developers and end‐users to generate tool paths quickly, even for complex LMD tasks that have non‐standard welding strategies. The generated paths are translated into machine code, and can be tested for possible collisions via a machine simulation. LMD Cam3D will be presented for the first time at the EuroMold from November 27 ‐ 30, 2012 in Frankfurt at the Fraunhofer joint booth, hall 11‐ C66a.

EuroBLECH 2012 Web TV - Laser Technology