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Aerospace Industry


A Global Reach With over 5000 employees and operations based in Italy,


Avio supplies customers across four continents. Te engine applications include turbine components for business jets to medium and long-range commercial aircraſt. Among Avio’s current programs are the Pratt & Whitney PW100 family of engines. Users of this series of engine include Airbus, Boeing, Bombardier, Canadair, Embraer and Superjet. Among Avio’s many new aerospace engine initiatives is a 14,000-lb (6350-kg) turbofan for the EJ200 engine. In particular the Pomigliano D’Arco (NA) plant is the


center of excellence for the manufacturing of combustors, ex- haust and reheat modules. Te most important programs that involve the Combustor Center of Excellence are: • EJ200—Aſterburner module • PW800—Exhaust module • Sam146—Combustor module • T700—Turbine and exhaust module • PW100 & PT6—Combustors


In the manufacturing processes of these parts the intensive


use of the laser microdrilling technology is essential to meet the requirements of the project.


and drilling applications. In addition, fiber-laser technology is more energy efficient, requiring lower input power for a given level of average output power, and also requires less cooling. “In addition to introducing the fiber laser at Avio,” said


Mark Barry, vice president of sales for Prima Power Laser- dyne, “the 430BD combines tested and proven motion and process control capabilities in a new, smaller and more space- efficient platform. With higher velocity and acceleration, the third-generation BeamDirector used on this system has the exclusive Laserdyne contouring head design with C-axis [ro- tary] motion of 900°, and D-axis [tilt] motion of 300°. Among its many features are optical encoders for improved accuracy and repeatability, higher assist gas air-flow, adjustable mirrors for easy and accurate beam alignment and cassette mounted lens and cover slides for quick, accurate changeover.” According to Barry, “Avio’s new system uses the Laserdyne


S94P control, which includes a full complement of standard hardware and soſtware features. Tese include Automatic Fo- cus Control (AFC) for capacitive part sensing; patented Opti- cal Focus Control (OFC) for sensing of thermal barrier coated surfaces; ShapeSoſt soſtware for programming shaped holes; Breakthrough Detection for drilling clean, consistent holes


To meet aerospace customers’ changing needs, Avio has continuously innovated with its manufacturing processes and facilities.


To meet aerospace customers’ changing needs, Avio has


continuously innovated with its manufacturing processes and facilities. Tis is especially true in the area of laser material pro- cessing. Avio was an early adopter of laser drilling of effusion cooling holes in combustion liners and other high-temperature engine components. Avio’s history with laser processing dates back to the 1990s, when it began using Laserdyne systems at its manufacturing location in Pomigliano d’Arcon (Naples). Te company now will use seven Laserdyne systems with the addi- tion of the Laserdyne 430BD. Tis will be Avio’s first fiber-laser equipped system. Te new system replaces a Laserdyne 550 with Nd:YAG laser used primarily for sheetmetal trimming. Te Laserdyne 430BD will continue to be used for these cutting operations, but with its flexible laser machining platform in a compact layout and the integration of the fiber laser, it is equally useful in drilling and welding operations with little changeover effort and time required.


The 9-kW QCW Fiber Laser Te Laserdyne 430BD integrates a IPG 9-kW QCW


fiber laser with a wavelength of 1070 nm, similar to that of a Nd:YAG laser. Laserdyne’s testing at its Minnesota applica- tions lab and at installations around the world has shown that fiber-laser systems provide the potential for improved cutting


124 Aerospace & Defense Manufacturing 2013


with the minimum number of pulses; mapping; and numerous additional soſtware and hardware features. Tis control will also allow the customer to use programs created for different Laserdyne systems with little or no modification.” Te 430BD operates at speeds up to 800 ipm (0–20 m/min)


in all axes with bidirectional accuracy of 0.0005" (12.7 μm). Tis accuracy is throughout the system’s 585 × 408 × 508-mm work envelope, making it well suited for the demanding process validation requirements and reliability concerns of Avio’s aerospace customers. Accuracy of the system is certified to ISO 230-1:1996 and 230-2:2006 in accordance with Prima Power Laserdyne’s standard accuracy and repeatability test procedures.


Processing Accuracy with Automatic Focus Control Achieving a high level of accuracy from prototype to


production stages and from one job to another is possible because of the way Laserdyne designs and integrates its system features. Everything works together in a coordinated manner—the controller, soſtware, motion system, laser and process sensors. A good example is the Laserdyne Automatic Focus Con-


trol. It’s a feature Avio has used in its earlier Laserdyne systems and swears by. Avio has provided feedback to Laserdyne en-


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