5
Method for cleaning and stripping a turboshaft engine blade using a pulsed laser
The invention relates to the field of maintenance and repair of aeronautical parts, in
particular of the blades of a turboshaft engine.
A blade is understood to be a part having a surface capable of channelling an air flow in the
turboshaft engine, wherein this part may be movable (rotor blade) or fixed (stator blade).
Conventionally, in the course of a maintenance operation of a turboshaft engine it is
10 necessary to inspect the blades of the turboshaft engine in order to detect any defects such
as cracks or splits. A turboshaft engine blade includes a superalloy structural body covered
with a plurality of layers of material in order to form the coating of the blade. During its use
the coating of the blade wears and is eaten away and must be replaced in order to ensure
optimal operation of the blades. The replacement of the coating of a blade necessitates on
15 the one hand removing the worn coating and on the other hand applying a new coating to
the body of the blade.
In practice, following the removal of the worn coating the blade is inspected in order to detect
possible defects such as cracks or splits in the body of the blade. This makes it possible to
20 avoid a situation in which a blade of which the superalloy body has been damaged is coated
with a new coating.
It is known that a blade coating generally includes at least one metal layer covering the body
of the blade and a ceramic layer covering the metal layer. In the course of its operation, the
25 coating may develop oxides and may exhibit portions which are corroded or polluted (dirt,
grease, combustion residues, etc.). The metal layer of which the thickness is between 50
and 100 pm is conventionally designated "metal sut)-layer" by the person skilled in the art
whilst the ceramic layer of which the thickness is between 150 and 350 pm is conventionally
designated "thermal barrier". Such a coating is known from the application FR 2814473 A1
30 in the name of Snecma.
The method of removal of the worn coating of the blade includes a plurality of successive
steps such as steps of stripping, sanding and cleaning by means of jets of water and/or
immersion in acid baths. A method according to the prior art results in emissions of
35 dangerous substances into the atmosphere and into water, which present a drawback for the
environment. Moreover, such a method is long taking into account the various steps which
must be implemented consecutively.
In fact, as an example, in order to remove a coating from a turboshaft engine blade the
5 following steps are implemented:
cleaning of the surface of the blade in a non-aggressive manner in order to remove
all the oxides and pollutants present on the surface of the blade;
inspection of the cleaned surface of the blade in order to determine whether the
10 blade can be repaired; and
cleaning of the surface of the blade in an aggressive manner in order to remove the
different layers of the coating of the blade;
The cleaning referred to as "non-aggressive" includes steps of degreasing of the blade,
15 cleaning of the internal circuits of the blade and removal of the surface oxides.
The cleaning referred to as "aggressive" includes, for its part, steps of sanding of the blade,
stripping of the thermal barrier, stripping of the metal sub-layer and other layers, cleaning of
the surfaces and splits in the superalloy blade body, and cleaning of the cooling channels of
20 the blade.
After repair of the body of the blade, a step of sanding is conventionally implemented in
order to give the body of the blade a roughness which favours the adhesion of a coating.
25 The different cleaning actions previously cited are generally implemented manually and
produce heterogeneous results depending upon the operators, in particular during the
sanding. In certain cases, the superalloy blade body can sometimes be damaged during the
cleaning and the blade must be scrapped. Furthermore, such a method can last for several
hours, which presents a drawback.
30
The present invention aims to eliminate at least some of these drawbacks in order to quickly
remove a coating from a turboshaft engine blade whilst respecting the environment and to
prepare the surface of the blade.
To this end the invention relates to a method for cleaning and stripping a turboshaft engine
blade comprising a superalloy body covered with a coating, in which the coating of the blade
is at least partially machined using a pulsed laser. A pulsed laser advantageously permits
removal of the coating locally without damage to the superalloy body of the blade.
5 Furthermore, laser machining makes it possible to provide a roughness on the body of the
blade, which avoids the use of an additional step of sanding. Moreover, no chemical product
is used, which limits the costs relating to the treatment of chemical waste.
Preferably, as the coating comprises at least one external ceramic layer the pulsed laser is
10 parameterised in order to machine only the external ceramic layer. Thus the damaged
ceramic layer can be replaced and a new external ceramic layer can be applied to the
cleaned surface.
Also preferably, as the coating comprises at least one external ceramic layer and one metal
15 layer disposed between the superalloy body and the ceramic layer, the pulsed laser is
parameterised in order to machine only the external ceramic layer and the metal layer. Thus
the damaged layers can be replaced and new layers can be applied to the cleaned surface.
According to one aspect of the invention, the pulsed laser is parameterised in order to
20 machine the entire coating of the blade (ceramic layer and metal layer). Thus the damaged
coating can be replaced and a new coating can be applied to the superalloy body, the
surface of which has been prepared and has the desired roughness.
In a preferred manner, at least the feed rate of the pulsed laser and the pulse frequency of
25 the pulsed laser are parameterised such that the machined surface of the blade has a
roughness of 4 pm to 10 pm. This makes it possible in an advantageous manner to apply a
new layer or a new coating taking advantage of an application surface which has good
qualities of adhesion.
30 The feed rate of the pulsed laser is preferably between 25 mm/s and 1000 mm/s, preferably
between 100 mm/s and 600 mm/s. Such a rate makes it possible to ensure a good
compromise between the depth of machining and the rate of machining.
More preferably, the pulse frequency of the pulsed laser is between 12 kHz and 50 kHz,
preferably less than or equal to 16 kHz. Such a frequency makes it possible to ensure a
good compromise between the depth of machining and the rate of machining.
5 The roughness is preferably constant over the machined coating so as to allow a
homogeneous adhesion of a new coating and therefore an increase in the service life
thereof.
Preferably, as the coating comprises a plurality of layers, the pulsed laser machines the
10 layers of the coating by carrying out a plurality of machining passes, the number of
machining passes for a layer being defined as a function of the thickness of the layer and the
hardness of the material of the layer. Thus the same parameterisation of the laser can be
retained in order to machine a plurality of layers, and only the number of passes has to be
parameterised as a function of the nature of the layers.
15
20
Again preferably, the pulsed laser is moved along machining lines on the coating, two
consecutive machining lines overlapping. Thus a homogeneous distribution of the bumps
and the hollows forming the roughness of the stripped surface is obtained, which enables
optimal adhesion of a new coating.
According to one aspect of the invention, a controller moves the pulsed laser in the course of
the machining along a defined trajectory based on three-dimensional modelling of the blade
to be cleaned.
25 Due to the use of a controller the cleaning of the blades is homogeneous and precise and
the risk of injury to an operator is limited.
The invention will be better understood when reading the following description given solely
by way of example and with reference to the appended drawings, in which:
30
Fig. 1 shows a schematic view of machining of a portion of the coating of a turboshaft
engine blade using a pulsed laser controlled by an automated robot;
Fig. 2 shows a schematic sectional view of a coating of a blade during laser
machining thereof;
Fig. 3A shows laser machining lines spaced apart from one another by a first
distance El;
Fig. 3B shows laser machining lines spaced apart from one another by a second
distance E2;
5 - Fig. 4A shows three laser machining lines each including a plurality of machining
points, the machining lines being respectively formed by a pulsed laser of which the
pulse frequencies are different;
Fig. 4B shows three laser machining lines each including a plurality of machining
points, the machining lines being respectively formed by a pulsed laser of which the
10 feed rates are different;
Fig. 5A is a sectional view of a coating of a turboshaft engine blade for a first
embodiment of the invention;
Fig. 5B shows a comparable sectional view of the surface of the blade of Fig. 5A
after the laser machining;
15 - Fig. 6A is a sectional view of a coating of a turboshaft engine blade for a second
embodiment of the invention; and
Fig. 68 shows a comparable sectional view of the surface of the blade of Fig. 58
after the laser machining.
20 With reference to Figs. 1 and 2, the invention relates to a method for cleaning a turboshaft
engine blade 1 having a superalloy body 13 covered with a coating 10. In this example the
coating 10 of the blade 1 includes a metal layer 12 covering the body of the blade 13 and a
ceramic layer 11 covering the metal layer 12. The metal layer 12 of which the thickness is
between 50 and 100 |jm is conventionally designated "metal sub-layer" by the person skilled
25 in the art whilst the ceramic layer 11 of which the thickness is between 150 and 350 pm is
conventionally designated "themrial barrier".
By the method of cleaning according to the invention, the coating 10 of the superalloy body
13 of the blade 1 is removed by means of a pulsed laser 3 as shown schematically in Fig. 1.
30
By way of example, the pulsed laser 3 is a laser of the yttrium aluminium garnet type, better
known by its abbreviation YAG, the power of which is approximately 20 W. As shown in Fig.
1, the beam 2 of the pulsed laser 3 is directed onto the surface of the blade 1 in order to
machine the coating 10 of the blade 1, the pulsed laser 3 making it possible to cause the
35 coating 10 to explode in a localised manner without damaging the body 13 of the blade 1
which is very advantageous. Furthemiore, no harmful product is used, which respects the
environment. Moreover, from the point of view of safety, the laser machining is preferably
carried out by means of an automated robot 4 so as to limit the risk of injuries to operators.
Thus, advantageously, each blade 1 is cleaned homogeneously and reproducibly.
5
The pulsed laser 3 is preferably connected to a controller 4 arranged in order to move the
laser 3 on the surface of the blade 1 along a predefined trajectory. Preferably, the machining
trajectory of the laser 3 is parameterised by a three-dimensional modelling of the blade 2
which is supplied to the controller 4. The pulsed laser 3 is preferably oriented in a direction
10 nomrial to the surface of the blade 1 so as to enable optimal stripping of the coating 10 of the
blade 1.
In order to remove the coating 10 from the blade 1, the laser beam 2 sweeps the coating 10
of the blade 1 starting from one end.of the blade 1. The laser beam 2 is preferably moved in
15 a rectilinear manner along a machining line 20, each machining line 20 being formed by a
plurality of machining points 21, aligned in a rectilinear manner as shown in Figs. 3A, 3B, 4A,
4B, each machining point 21 corresponding to a pulse of the pulsed laser 3.
The pulsed laser 3 is parameterised in such a way as to enable rapid removal of the coating
20 10 without damaging the body of the blade 13. Furthermore, the pulsed laser 3 can be
parameterised in order to remove all or part of the coating 10 of the blade 1. To this end, a
plurality of parameters of the pulsed laser 3 can be taken into account such as the width of
the laser beam 2, the spacing E of the laser lines, the frequency F of the laser pulses, the
pulse time, the focal distance, the feed rate V of the beam, the power of the laser and the
25 number of passes on the blade. According to the invention, as will be detailed below, at least
the feed rate of the pulsed laser and the pulse frequency of the pulsed laser are
parameterised such that the machined surface of the blade has a roughness of 4 pm to 10
pm.
30 The roughness is a surface state of the blade after stripping. On the surface of the blade this
leads to the presence of a relief formed of hollows and bumps. The roughness value is
defined as the distance between the top of a bump and the cavity of a hollow. A roughness
of controlled and constant value over the blade makes it possible in an optimal and rapid
manner to apply a new coating by adhesion to the bumps of the stripped surface of the
35 blade.
• Width of the laser beam
The width of the beam 2 corresponds to the surface for application of the power of the laser
5 beam 2 during its contact with the coating as shown schematically in Fig. 3A. The narrower
the t)eam 2, the more concentrated the power of the beam 2, which increases the impact of
the beam 2 on the coating 10 and therefore the thickness of the coating which will be
removed for an individual pulse of the laser 3, i.e. for a machining point 21 of a machining
line 20. The width of the laser beam 2 is preferably equal to 0.01 mm, 0.03 mm or 0.05 mm
10 in such a way as to form machining points 21 of which the diameter is equal to 0.01 mm,
0.03 mm or 0.05 mm. Consequently the width of the laser beam 2 is equal to 0.03 mm,
which ensures a good compromise between the machining surface and the depth of
machining.
15 • Pulse time
The pulse time defines the period during which the laser beam 2 is in contact with the
coating 10 on a given machining point 21. The longer the pulse duration, the more
considerable the thickness of the coating 10 removed for an individual pulse of the laser 3.
20 Consequently the laser beam 3 is parameterised with a pulse time of approximately 3 ps
which ensures a good compromise between the machining rate and the depth of machining.
• Spacing E of the laser lines
25 As shown in Figs. 3A and 3B, the laser beam 2 moves in a rectilinear manner along parallel
machining lines 20, each machining line 20 being formed by a plurality of machining points
21 which are aligned in a rectilinear manner.
The spacing E between the machining lines makes it possible to define a covering surface
30 between two machining lines 20 which are adjacent. With reference to Fig. 3A, if the
machining lines 20 are close to one another (spacing El), the overlap of the machining lines
20 is substantial, which may present a risk of excessive machining of the coating 10. On the
other hand, with reference to Fig. 3B, if the machining lines 20 are spaced apart from one
another (spacing E2), the coating 10 situated between the adjacent machining lines 20 is not
35 removed, which is a drawback. Preferably the spacing E between the machining lines 20 is
parameterised in such a way that it is less than the width of the beam 2 in order to enable a
coverage greater than half of the width of the beam 2 so as to eliminate any lack of
machining and to avoid excessive machining. In this example, for a width of the laser beam
2 equal to 0.03 mm, the space E between the machining lines 20 is equal to 0.025 mm.
5
Advantageously, two successive machining lines overlap so as to allow a homogeneous
roughness to be obtained on the machined surface of the blade 1 and thus to enable the
application of a new coating with optimal adhesion.
10 - Focal length
This parameter is defined for a given pulsed laser 3 and indicates the distance at which the
laser beam 3 has the previously defined width of beam 2. This parameter must be respected
in order to control the width of the beam and hence its power. Consequently consideration is
15 given to a YAG laser 3 of focal length equal to 20 cm, which corresponds in this example to
the distance between the window of the laser and the point of impact on the blade being
treated.
20
25
• Frequency F of pulses of the laser 3 and feed rate V of the laser beam 2
The frequency F of the laser beam 2 defines the frequency of the pulse train. During the
laser machining, the frequency F is directly associated with the feed rate V of the beam 2 in
order to define the spacing d between two consecutive machining points 21 of one and the
same machining line 20, as shown in Figs. 4A-4B.
For a given machining line 20, with a constant feed rate V, the higher the frequency F of the
pulses, the closer the machining points 21 are to one another. By way of example, with
reference to Fig. 4A, the machining lines 20A, 208, 20C are formed with a pulsed laser 3 of
constant feed rate V, equal to 250 mm/s, and of which the pulse frequencies are respectively
30 equal to 5 kHz, 12 kHz and 25 kHz. The higher the frequency of the pulses, the more the
distance d1, d2, d3 separating consecutive machining points 21 is reduced. In practice, any
frequency F between 12 kHz and 50 kHz is compatible.
The feed rate V of the laser beam 2 is defined according to the direction of a machining line
35 20. Thus for a given machining line 20, for a constant pulse frequency F, the distance
separating consecutive machining points 21 is a function of the feed rate V. By way of
example, with reference to Fig. 4B, the machining lines 20D, 20E, 20F are fomied with a
pulsed laser 3 of constant frequency F, equal to 12 kHz, and of which the feed rates V are
respectively equal to 125 mm/s, 250 mm/s and 500 mm/s. The higher the feed rate, the
5 greater the distance d4, d5, d6 separating consecutive machining points 21. In practice, any
feed rate V between 25 mm/s and 1000 mm/s is compatible.
Preferably, for one and the same layer to be machined, the pulsed laser 3 has the same
parameterisation at each pass. Thus, the greater the thickness of a layer to be removed, the
10 higher the number of passes. Preferably also, for one and the same coating to be machined,
the pulsed laser 3 has the same parameterisation at each pass for each of the layers. The
number of passes is defined as a function of the thickness and the hardness of the material
of each layer.
15 According to a first embodiment of the method according to the invention, only the ceramic
layer 11 of the coating 10 of the blade 1 is removed by means of the pulsed laser 3, said
laser being parameterised as follows:
Width of the beam: 0.03 mm
20 - Spacing E of the laser lines: 0.025 mm
Frequency F of the laser pulses: 12 kHz
Pulse time: 3 ps
Focal length: 20 cm
Feed rate V of the beam: 250 mm/s
25
In order to entirely remove the ceramic layer 11, 50 passes of the laser beam 3 are made on
the coating 10. In other words, for a defined machining line 20 on the coating 10, the laser is
moved 50 times on said machining line 20 in the course of the method of cleaning, which
makes it possible to remove the coating 10 progressively with the passes of the laser beam
30 2.
With reference to Figs. 5A and 58 showing a sectional view of the coating after machining,
the first embodiment of the method according to the invention makes it possible to
selectively remove the ceramic layer 11 of the coating 10 of which the thickness is
35 approximately 200 pm. As shown in Fig. 5A, the ceramic layer 11 has only been partially
10
removed from the blade 1, the blade 1 thus including an uncleaned surface S1 consisting of
the ceramic layer 11 and a cleaned surface S2 consisting of the metal layer 12 after laser
machining.
5 Advantageously, with reference to Fig. 5B showing a comparable view of the cleaned
surface S2, the roughness of the cleaned surface S2 of the coating 10 after laser machining
is approximately 7 to 9 pm. The roughness of the cleaned surface S2 advantageously
makes it possible to deposit a new ceramic layer 11 directly on the metal layer 12 without
previously carrying out a step of sanding, as is the case in the methods according to the
10 prior art. In other words, the cleaning of the blade by means of a pulsed laser 3 makes it
possible, on the one hand, to remove all or part of the coating 10 and, on the other hand, to
prepare the cleaned surface S2 to receive a new protective layer, in this case a new ceramic
layer 11.
15 A second embodiment of the invention is described with reference to Fig. 6A. The references
used to describe the elements with an identical, equivalent or similar structure or function to
those of the elements of Fig. 5A are the same, in order to simplify the description. Moreover,
not all of the description of the embodiment of Fig. 5A is reproduced, this description
applying to the elements of Fig. 6A when there are no incompatibilities. Only the significant
20 structural and functional differences are described.
According to the second embodiment, the pulsed laser is parameterised in an identical
manner to the first embodiment, only the frequency F of the pulses of the laser and the feed
rate V being modified. In this embodiment, the pulse frequency F of the laser is 16 kHz and
25 the feed rate V is 500 mm/s. In a similar manner to the first embodiment, the pulsed laser 3
performs approximately 50 passes on the coating of the blade 1 in the course of the method
of cleaning, which makes it possible to remove the coating progressively with the passes of
the laser beam 2.
30 With reference to Figs. 6A and 6B, the second embodiment of the method according to the
invention also makes it possible to selectively remove the ceramic layer 11 of the coating 10.
Advantageously, the roughness of the surface of the coating 10 after laser machining is 4 to
6 pm as shown in Fig. 68. Thus the desired roughness is advantageously parameterised by
modifying the pulse frequency F of the laser and the feed rate V.
35
11
According to a third embodiment of the method according to the invention, the coating 10 of
the blade 1 is entirely removed by means of the pulsed laser 3. In other words, all the layers
of the coating 10 of the blade 1 are removed, including the ceramic layer 11 and the metal
layer 12. To this end, the pulsed laser 3 is parameterised as follows:
5
Width L of the beam: 0.03 mm
Spacing E of the laser lines: 0.025 mm
Frequency F of the laser pulses: 12 kHz
Pulse time: 3 ps
10 - Focallength: 20 cm
Feed rate V of the beam: 250 mm/s
In this third embodiment, the pulsed laser 3 performs approximately 250 passes on the
coating 10 of the blade 1 in the course of the method of cleaning, which makes it possible to
15 remove the coating 10 progressively with the passes of the laser beam 2. The number of
passes here is greater by comparison with the preceding embodiments of the method in
order to increase the thickness of the coating 10 to be removed. These parameters make it
possible to strip the ceramic layer 11 and the metal layer 12 which make up the coating 10.
20 In a particular embodiment, the substrate can be machined in order to obtain the desired
roughness and thus to enable the adhesion of a new coating.
After removal of the coating 10, the superalloy body 13 is bare, which advantageously
makes it possible to inspect its surface in order to detect any defects before application of a
25 new coating 10.
In a similar manner to the first embodiment of the method according to the invention, the
roughness of the cleaned surface, that is to say the surface of the superalloy body 13, is
approximately 7 to 9 pm. This roughness advantageously makes it possible to deposit a new
30 metal layer 12 directly on the superalloy body 13. It is then sufficient to deposit a new
ceramic layer 11 on the metal layer 12 in order to form the coating 10. Because of the
overlapping of the machining lines, the roughness obtained is homogeneous over the
treated surface of the blade, the treated surface having hollows and bumps regularly spaced
apart from one another.
35
12
10
According to a fourth embodiment of the invention, the coating 10 of the blade 1 is entirely
removed by means of the pulsed laser 3 parameterised as set out below:
Width L of the beam: 0.03 mm
Spacing E of the laser lines: 0.025 mm
Frequency F of the laser pulses: 16 kHz
Pulse time: 3 |js
Focal length: 20 cm
Feed rate V of the beam: 350 mm/s
In this fourth embodiment, the pulsed laser 3 performs approximately 100 passes on the
coating 10 of the blade 1 in the course of the method of cleaning, which makes it possible to
remove the coating 10 (the ceramic layer 11 and the metal layer 12) progressively with the
passes of the laser beam 2. The number of passes here is greater by comparison with the
15 first two embodiments of the method in order to increase the thickness of the coating 10 to
be removed. After removal of the coating 10, the superalioy body 13 is bare, which
advantageously makes it possible to inspect its surface in order to detect any defects before
application of a new coating 10.
20 The parameters of this fourth embodiment of the invention make it possible to strip the layers
11 and 12 fomiing the coating 10 by obtaining a roughness of 4 to 6 pm of the surface of the
superalioy body 13. Such a roughness is advantageous for depositing a new metal layer 12.

13 .--rcT^^i^' 0 m^ WQ
W i Ubl^v-'^ I
Claims 10 1% o --'• ^ ^
1. Method for cleaning and stripping a turboshaft engine blade (1) comprising a
superalloy body (13) covered with a coating (10), in which the coating (10) of the blade (1) is
5 at least partially machined using a pulsed laser (3), at least the feed rate (V) of the pulsed
laser (3) and the pulse frequency (F) of the pulsed laser (3) being parameterised such that
the machined surface of the blade (1) has a roughness of 4 pm to 10 pm.
2. Method according to claim 1, wherein as the coating (10) comprises at least one
10 external ceramic layer (11) the pulsed laser (3) is parameterised in order to machine only the
external ceramic layer (11).
3. Method according to claim 1, wherein as the coating (10) comprises at least one
external ceramic layer (11) and one metal layer (12) disposed between the superalloy body
15 (13) and the ceramic layer (11), the pulsed laser (3) is parameterised in order to machine
only the external ceramic layer (11) and the metal layer (12).
4. Method according to claim 1, wherein the pulsed laser (3) is parameterised in order
to machine the entire coating (10) of the blade (1).
20
5. Method according to any one of claims 1 to 4, wherein the feed rate (V) of the pulsed
laser (3) is between 25 mm/s and 1000 mm/s, preferably between 100 mm/s and 600 mm/s.
6. Method according to any one of claims 1 to 5, wherein the pulse frequency (F) of the
25 pulsed laser (3) is between 12 kHz and 50 kHz, preferably less than or equal to 16 kHz.
7. Method according to any one of claims 1 to 6, wherein the roughness is constant
over the machined coating (10).
30 8. Method according to any one of claims 1 to 7, wherein as the coating comprises a
plurality of layers, the pulsed laser machines the layers of the coating by carrying out a
plurality of machining passes, the number of machining passes for a layer being defined as a
function of the thickness of the layer and the hardness of the material of the layer.
% *
14 1^ SOM l t l«
10
9. Method according to any one of claims 1 to 8, wherein the pulsed laser is moved
along machining lines on the coating (10), two consecutive machining lines overlapping.
10. Method according to any one of claims 1 to 9, wherein a controller (4) moves the
pulsed laser (3) in the course of the machining along a defined trajectory based on threedimensional
modelling of the blade (1) to be cleaned.