Aiming at the problem of deformation of titanium alloy thin plate welding, a coaxial dual-beam laser composed of continuous laser and pulsed laser was used to test the welding of 1.5 mm thick Ti–6Al–4V thin plate. The effect of different laser power ratios, pulse widths, and frequencies on weld formation and sheet deformation is investigated, and the optimum welding process parameters for butt welding of Ti–6Al–4V sheet are determined. The test results show that the welding process parameters of continuous laser power of 1.6 kW, pulsed laser power of 0.3 kW, pulse frequency of 25 Hz, pulse width of 6 ms, and welding speed of 1000 mm/min can obtain a weld with excellent quality and the deformation angle of 0.9°. The tensile strength of the welded joint is 948 MPa, reaching 92.3% of the base material; the maximum residual compressive stress on the weld surface is 207 MPa, and the microhardness of the weld zone and the heat-affected zone is higher than that of the base material.

Making shaped film holes in hot section’s components of aero-turbine can improve cooling efficiency remarkably. The paper briefly describes the technical way of making shaped hole by 2 – 3 ps laser and presents high quality shaped holes made by this way after optimizing processing technical parameters in single crystal super alloy with thermal barrier coatings. Based on optimized ps laser making hole technology, flat specimens in which round holes or forward leaning fan-shaped holes have been made were used to do high cycle tensile fatigue test and high cycle vibration fatigue test at high temperature condition; turbine blades in which only round holes have been made and turbine blades also including forward leaning fan-shaped holes or swallowtail shaped holes were used to do cooling effect test. The results show that the fatigue strength of flat specimens with shaped holes is better and the cooling effect of turbine blades with shaped holes is also better, the cooling efficiency of turbine blade with forward leaning fan-shaped holes is higher than that of turbine blade with swallowtail shaped holes.

The life of the blades is affected in varying degrees by traditional micro pore machining techniques like drilling and EDM, which cannot match the requirements of high precision and high quality of the holes due to issues like significant taper, recast layer, and cracks during the machining process. Different from traditional mechanical processing, laser processing micro-holes is a high-precision processing method. However, since the spatter cannot completely expel the pores, a recast layer is formed on the hole wall, which affects the quality of the vias. In this paper, the simulation study of the femtosecond laser processing process of micro-holes is carried out and the morphology changes of the micro-holes from the beginning of ablation to the end of the micro-holes are analyzed, and then by changing different laser parameters, it is concluded that the thickness of the recast layer is affected by the laser power and pulse width, and the thickness of the recast layer can be reduced by increasing the power, but the power cannot be increased indefinitely, which will cause excessive ablation, and the pulse width does not show a simple linear relationship with the thickness of the recast layer. In order to reduce the thickness of the recasting layer, a processing method of reaming is proposed, which is to process micropores that are smaller than the actual requirements, and then expand the holes. It is verified by experiments that reaming can significantly improve the quality of micro-pores.

Silicon carbide ceramic matrix composites (SiC_f /SiC and C_f /SiC) (CMC-SiC), as typical difficult-tomachine materials, have demonstrated significant application potential in extreme service environments such as aerospace and national defense due to their excellent high-temperature resistance, oxidation resistance, and high strength. This paper systematically reviews the current research status of laser processing technologies for CMC-SiC, including continuous laser and long/short pulse laser processing, as well as ultrafast pulse laser processing in the field of material machining.Additionally, it explores the enhancement effects of various energy fields such as gas, liquid, ultrasonic vibration, and electromagnetic fields combined with laser processing on machining quality. This paper analyzes critical issues encountered during laser processing, such as heat-affected zones, oxidation layers, interlayer cracking, and fiber pull-out. Furthermore, it summarizes the current research achievements in multi-energy field collaborative processing of CMC-SiC, providing references to promote the in-depth development and application of multi-energy field composite processing techniques.

Laser technology plays an important role in the field of aerospace manufacturing. In addition to the laser acting alone on the processing process, there are various multi-energy field composite manufacturing methods based on laser technology. However, the inherent mechanisms of these composite manufacturing methods still need to be explored in depth. In response to the above challenges, the molecular dynamics (MD) method is used as a powerful tool to explore the coupling mechanism between multi-energy fields, optimize the processing parameters of composite manufacturing methods, and explore other micro-nano processing methods. This paper reviews the application of MD in multi-energy field composite manufacturing based on laser technology, and outlines the corresponding processing principles and MD simulation schemes for different composite manufacturing methods. The model design of MD simulation and the whole process of composite processing based on laser technology in different processing scenarios are discussed. In addition, this paper introduces the challenges and solutions faced in this field, and tries to determine future research directions based on existing knowledge and technology.

In the aerospace domain, ultrasonic vibration-assisted nanosecond laser processing technology has been demonstrated to significantly reduce surface roughness by mitigating the heat-affected zone and surface defects during processing. This technology plays a crucial role in enhancing the fatigue life and corrosion resistance of aircraft components, thus ensuring their safety and reliability. The objective of this study is to investigate the effects of ultrasonic vibration and laser power on the nanosecond laser ablation process. Based on the principles of laser thermodynamics and ultrasonic mechanism, a thermodynamic model for fixed-point pulse ablation with and without ultrasonic assistance was established. The accuracy of the simulation results was validated through experiments. Microscopic morphologies of both nanosecond laser processing (NLP) and ultrasonic vibration-assisted nanosecond laser processing (UVNLP) were compared using simulation and experimental approaches. Results indicate that as laser power increases, the diameter and depth of ablation pits increase, surface roughness rises, the slope of ablation pits increases, and the rate of depth increase exceeds that of diameter. The introduction of ultrasonic vibration reduces pit diameter by 1.4–2.0 μm and surface roughness by 0.092–0.208 μm compared to conventional NLP, thereby significantly improving surface quality. This improvement is essential for extending the service life of aircraft components and reducing maintenance costs.

Aiming at the problems of complicated design and low manufacturing efficiency of aviation catheter welding tooling, this paper studied the rapid design scheme of aviation catheter welding tooling, established the standard positioning component library, and proposed the constraint algorithm between positioning component and catheter and the key algorithm of parametric construction of non-standard support. Based on CATIA, the rapid design software of aviation conduit welding tooling was developed to realize the rapid design of aviation conduit welding tooling and the rapid assembly of standard parts. The fast design algorithm studied in this paper is applied to the software, and the results show that the software design time is reduced by 97% compared with the traditional design method, which provides a method for enterprises to reduce costs and improve efficiency, and has certain engineering practical application significance.

In order to improve the qualification rate of gas turbine hollow turbine blades, non-destructive testing technologies such as X-ray computed tomography (CT), three-dimensional scanning (3D) and ultrasound were used to carry out dimensional measurement of turbine blades in key stages of investment casting, and the whole process of ceramic core, wax mold, mold shell and blade castings was realized. The results show that the CT technology can meet the measurement accuracy requirements of ceramic core and wax mold, and is further applied to the measurement of mold shell size. In addition, the dimensional accuracy of ceramic core, wax mold and mold shell, inner cavity and wall thickness can be detected and evaluated by using CT. The dimensional measurement method of the whole process of hollow turbine blade preparation established in this study provides strong data support for ensuring the preparation of hollow turbine blades and improving the qualified rate of large-size hollow turbine blade precision casting products.

As an important channel for energy transmission in aero-engines, the fatigue strength and reliability of aviation high-pressure pipeline system have a direct impact on the flight performance and service life of aircraft. Based on the three shear unified strength criterion, a bilinear dynamic strengthening model considering material strain hardening and Bauschinger effect was adopted to establish a finite element analysis model for the autofrettaging treatment of typical aviation high-pressure pipelines. Analyze the distribution pattern of residual compressive stress after autofrettaging treatment of stainless steel, aluminum alloy, and titanium alloy pipelines; Conduct simulation analysis and experimental verification on the fatigue life of stainless steel pipelines; Calculate the mechanical response results of the internal to external diameter ratio and bending angle of aviation high-pressure pipelines to autofrettaging treatment. The results show that compared with other materials, titanium alloy pipelines with autofrettaging treatment will achieve a better residual compressive stress state; At the same time, analyzed the residual compressive stress state after bending treatment and under working load, and based on the variation law of residual compressive stress with diameter ratio and bending angle, the range of diameter ratio and bending angle for obtaining the best self strengthening treatment effect of the pipeline was determined. The stress state of the bend under working state was analyzed, and the method of selecting autofrettaging pressure when there are multiple bending angles on the pipeline was analyzed, providing a theoretical basis for the application of autofrettage in aviation high-pressure pipelines.

In-situ analysis and testing system based on the scanning electron microscope platform and compact mechanics platform can track the dynamic evolution process of characteristics for micro-scale and nano-scale structures and fractures during sample deformation in real time, dynamically, and continuously. It can more efficiently and accurately reveal the failure modes and mechanisms of materials, and then achieving iterative optimization of structures and properties by adjusting key characteristics of microstructures. The applications of in-situ analysis and testing technology based on scanning electron microscope in key aviation structural materials such as superalloys, titanium alloys, aluminum alloys, composite materials, high-strength steels, and high entropy alloys are summarized. It will provide new ideas for the study of material damage evolution and deformation behavior in aviation structural materials, and further promote the application of in-situ analysis and testing technology in the research and industrialization of aviation structural materials.

This paper studies the efficiency differences between multi-axis and single-axis EDM using a spark link algorithm. A main direction ingestion interpolation algorithm was designed and developed, based on various linkage requirements and EDM process characteristics. Compared with the traditional point-by-point comparison method, this algorithm can improve linkage efficiency. By analyzing the consumed acceleration and deceleration time and continuous motion time, the efficiency of single-axis and linkage interpolation under non-discharge and discharge conditions was compared. The results show that multi-axis linkage has a significant efficiency loss compared to single-axis motion. Furthermore, the main direction ingestion interpolation algorithm can effectively reduce the efficiency loss caused by linkage. Under non-discharge conditions, the maximum value of efficiency loss for two-axis linkage is about 25.47%, and the maximum value of efficiency loss for three-axis linkage is about 46.30%, and the results fluctuate depending on the continuous feed ratio of single-axis motion. Under discharge conditions, in terms of material removal rate comparisons, the two-axis linkage improved by about 7.91%, and the three-axis linkage improved by about 11.92%.

In order to research the stacking sequence design method of resin based composite material horizontal tail in VARI molding process and obtain the optimal laminate scheme, a numerical model for strength analysis of composite material horizontal tail was established, and a preliminary plan for layering of horizontal tail was obtained. We designed and manufactured test pieces and test fixtures for the horizontal tail wing, and applied critical loads according to the requirements of article 23.423 of CCAR—23 for maneuvering loads to complete the test verification. The measured values of the test are in good agreement with the calculated values at the corresponding positions, indicating that the established numerical model is effective. Based on the displacement and stress-strain results, the optimization design of the paving sequence for the spar cap was carried out. The optimization results show that, under the same proportion of paving layers at different angles, the paving sequence had little effect on the overall stress distribution of all paving layers of the edge strip, but had an impact on the maximum stress value. The optimal plan of 3 layers and 1 group of laminating layers obtained through the sequence optimization research can be used for the paving design of the horizontal tail spar cap.