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<p>The need to create blind features is common across many engineering sectors. Where the pocket size must be less than a few millimetres, conventional machining becomes unsuitable. Laser machining offers a potential alternative for micromachining, with water jet–guided laser (WJGL) technology being particularly suited for challenging materials. This paper uses a 532-nm nanosecond laser to investigate WJGL machining of pocket features. Blind machining trials were performed across 3 different materials (Nickel C263, titanium alloy, and tungsten carbide) to improve the understanding of the kinematic parameters (i.e. non-laser) with the aim of being material agnostic. A systematic study was conducted to understand the influence of scan pattern, hatch spacing, and number of passes on the material removal rate (MRR) and base surface roughness. Wall taper was also measured and found to be under 8°. The findings demonstrate WJGL technology to be highly effective, with a maximum MRR of 11.0 mm<sup>3</sup>/min for the C263, 15.2 mm<sup>3</sup>/min for the Ti-6Al-4&#xa0;V, and 2.1 mm<sup>3</sup>/min for the WC. This exceeds that reported for conventional laser machining and EDM, making the technology a promising option for the generation of blind features in various materials and application to industry.</p>

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Water jet–guided laser machining of advanced materials

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • Ben Mason,
  • Helen Elkington,
  • Mitchell Leering,
  • Aidan Cloonan,
  • Donal McCarthy,
  • Eddie Kavanagh,
  • Sundar Marimuthu

摘要

The need to create blind features is common across many engineering sectors. Where the pocket size must be less than a few millimetres, conventional machining becomes unsuitable. Laser machining offers a potential alternative for micromachining, with water jet–guided laser (WJGL) technology being particularly suited for challenging materials. This paper uses a 532-nm nanosecond laser to investigate WJGL machining of pocket features. Blind machining trials were performed across 3 different materials (Nickel C263, titanium alloy, and tungsten carbide) to improve the understanding of the kinematic parameters (i.e. non-laser) with the aim of being material agnostic. A systematic study was conducted to understand the influence of scan pattern, hatch spacing, and number of passes on the material removal rate (MRR) and base surface roughness. Wall taper was also measured and found to be under 8°. The findings demonstrate WJGL technology to be highly effective, with a maximum MRR of 11.0 mm3/min for the C263, 15.2 mm3/min for the Ti-6Al-4 V, and 2.1 mm3/min for the WC. This exceeds that reported for conventional laser machining and EDM, making the technology a promising option for the generation of blind features in various materials and application to industry.