Fabrication of cooling holes using laser machining and ultrasonic machining

A method of machining cooling holes, the method comprising:

• providing a ceramic airfoil in which cooling holes are to be formed, wherein the cooling holes once formed each define distinct first and second sections, the ceramic airfoil being secured in a fixture that is mounted in a first machine;
• in the first machine, using a laser to drill through-holes in the ceramic airfoil, each of the through-holes being spatially common to the first and second sections of a respective one of the cooling holes;
• after drilling the through-holes, removing the fixture with the ceramic airfoil secured therein from the first machine and mounting the fixture in a second machine;
• in the second machine, using ultrasonic machining to expand a portion of each of the through-holes to form the second section;
• and
• draining an abrasive slurry through the through-holes during the ultrasonic machining.