Method for producing shaped hole in a structure

A method for producing a shaped hole in a structure, comprising the steps of:

• (a) emitting a first predetermined number of pulses from a laser system to a first focal point on said structure thereby creating a cavity in said structure;
• (b) emitting a second pre determined number of unmodulated pulses from said laser system to a second focal point on said structure such that said unmodulated pulses pass through at least a portion of said cavity and create a hole through said structure, each of said unmodulated pulses having an effective diameter, an intensity and a pulse width;
• (c) emitting at least one macro pulse from said laser system into the hole, said macro pulse comprising a series of modulated pulses, said modulated pulse having an effective diameter at least as great as the effective diameter of said unmodulated pulse, said modulated pulse having an intensity greater than the intensity of said unmodulated pulse, said modulated pulse having a pulse width less than the pulse width of said unmodulated pulse;
• and
• (d) milling the cavity portion of the hole.

A method for producing a shaped hole in an airfoil, comprising the steps of:

• (a) emitting a first predetermined number of modulated pulses from a laser system to a first focal point on an airfoil thereby creating a cavity in said airfoil;
• (b) emitting a second predetermined number of unmodulated pulses from said laser system to a second focal point on said airfoil such that said unmodulated pulses pass through at least a portion of said cavity and create a hole through said airfoil, each of said unmodulated pulses having an effective diameter, an intensity and a pulse width;
• (c) emitting a third predetermined number of unmodulated pulses from said laser system into the hole;
• (d) emitting at least one macro pulse from said laser system into the hole, said macro pulse comprising a series of modulated pulses, said modulated pulse having an effective diameter at least as great as the effective diameter of said unmodulated pulse, said modulated pulse having an intensity greater than the intensity of said unmodulated pulse, said modulated pulse having a pulse width less than the pulse width of said unmodulated pulse;
• and
• (e) milling the cavity portion of the hole utilizing a mechanical milling tool.

A method for producing a shaped hole in a structure comprising the steps of:

• (a) mechanically drilling a cavity in a structure;
• (b) emitting a pulsed laser beam from a laser system and focusing said pulsed laser beam at a focal point such that said pulsed laser beam passes through at least a portion of said cavity within said structure, said pulsed laser beam penetrating through said structure, thereby forming a shaped hole within said structure;
• and
• (c) milling the cavity portion of the shaped hole.