A Review of the Machining of the Film Cooling Holes with Thermal Barrier Coatings Through Non-traditional Machining Methods

As the aviation industry continues to expand, increasing demands are being placed on aviation engines to withstand extreme temperatures, making it essential to effectively disperse heat from turbine blades. Studies have shown that film cooling holes coated with thermal barrier materials can endure high temperatures and significantly increase engine operating temperatures, thereby enabling higher thrust-to-weight ratios. But, the structure of this insulating ceramic layer adhered to the metal surface presents a significant processing challenge. Consequently, a focal point of manufacturing research now centers on developing effective and high-quality methods for processing film cooling holes with thermal barrier coatings. Accordingly, this paper compares the advantages and disadvantages of various specialized machining techniques and reviews the research progress in processing film cooling holes with thermal barrier coatings, considering both single and composite techniques. Finally, it provides an overview of the future directions for film cooling hole machining methods with thermal barrier coatings. This advancement is crucial for enhancing the standards of aero engine manufacturing.