Hastelloy-X is a nickel-based superalloy predominantly using in engine combustion zone parts of gas turbines. Micro-holes are drilling to the surface of these parts for air-cooling passageways to improve part-life by reducing thermal fatigue. Laser, micro-electric discharge machining (µEDM), and micro electrochemical machining (µECM) are the major processes for creating holes in superalloys. Yet, if used individually, these techniques could end up with faulty holes. The sequential application of multiple drilling methods for hole-making will eliminate the defects. In this work, micro-holes have drilled on Hastelloy-X by using a laser in sequence with μEDM and laser in sequence with μECM. Holes produced by these two-hybrid approaches are later compared for productivity and quality features. Both form and productivity factors have been estimated, and optimal input combinations for each response have been identified from the mean analysis. The Pareto-Analysis of Variance has been used to determine the critical factors for each response. A detailed characterization study has been done to ensure the surface integrity of the holes. It has been found that micro-holes formed by sequential laser processing with μEDM improve the responses compared to the individual μEDM outputs. A similar improvement has also observed in laser combined with µECM holes concerning individual µECM. Both results collectively indicated that the novel sequential laser approach with µEDM is more efficient than the sequential application of laser with the µECM. This study provides clear guidance for the sequential micro-drilling of Hastelloy-X using numerous non-traditional drilling approaches.

Hastelloy-X 是一种镍基高温合金，主要用于燃气轮机的发动机燃烧区部件。在这些零件的表面钻出微孔作为空气冷却通道，通过减少热疲劳来提高零件寿命。激光、微放电加工 ( μ EDM) 和微电化学加工 ( μ ECM) 是在高温合金中形成孔的主要工艺。然而，如果单独使用，这些技术最终可能会出现错误的漏洞。连续应用多种钻孔方法进行孔加工将消除缺陷。在这项工作中，微孔通过提供具有序列使用激光钻出的Hastelloy-X μ与序列EDM和激光μECM。稍后将比较这些两种混合方法产生的孔的生产率和质量特征。已经估计了形式和生产力因素，并且已经从均值分析中确定了每个响应的最佳输入组合。方差的帕累托分析已用于确定每个响应的关键因素。已经进行了详细的表征研究以确保孔的表面完整性。已经发现，与单独的μ EDM 输出相比，通过使用μ EDM连续激光加工形成的微孔改善了响应。类似的改进也在激光联合观察到μ ECM孔有关个别μECM。这两个结果共同表明，采用µ EDM的新型顺序激光方法比采用µ ECM的激光顺序应用更有效。本研究为使用多种非传统钻孔方法对 Hastelloy-X 进行顺序微钻孔提供了明确的指导。