Synova SA, Duillier, Switzerland, a provider of advanced laser-cutting systems, has developed a CNC machine with 5-axis capability to satisfy stringent technical requirements in the aerospace and energy sectors. As engine manufacturers continuously seek to improve performance, high-quality machining of turbine engine components and process stability in production are critical to success. The new MCS 500 with waterjet-guided Laser MicroJet (LMJ) technology allows precise, fast 2D and 3D laser cutting and drilling of hot section components used in modern jet engines and industrial gas turbines with high repeatability.

The MCS 500 is based on a platform manufactured by Makino Milling Machine Co. Ltd., Tokyo. Thanks to Synova's "wet" laser process, the machine drills cylindrical cooling air holes in turbine blades and vanes and cuts complex geometries, such as diffuser shapes, without any heat damage. Superalloy turbine blades with nonconducting thermal barrier coating can be processed in one simple step without cracks or delamination in the ceramic coating and with extremely low recast.

"Synova's MCS 500 Laser MicroJet machine enables our customers to drill holes and to shape diffusers in components already pre-coated with a thermal barrier as opposed to post-coating drilling processes currently being used," said Dr. Bernold Richerzhagen, founder and CEO. "This approach significantly simplifies the overall process, improves quality and reduces overall manufacturing."

The LMJ machine also enables 3D machining of components that are made of new heat-resistant and ultrahard materials, such as ceramic matrix composites (CMCs) without affecting their basic structure. GE Aviation, Evendale, Ohio, is an aero-engine manufacturer that relies on Synova's MCS 500 for machining CMC shrouds for its LEAP engines.

The LMJ system can be flexibly incorporated into production as a standalone system or into automated lines for operator-free, high-volume production. The system is equipped with various interfaces that can be custom configured with automation and handling according to individual needs.

All MCS machines incorporate Synova's waterjet-guided laser technology, which generates a cylindrical laser beam within a hair-thin water jet, resulting in perfectly parallel walls, tight kerf widths, smooth cutting surfaces and sharp edges without a heat-affected zone and free of microcracks, oxidation and depositions.

Synova will premiere the system at EMO Hannover in Germany from Sept. 18 to 23 in hall 12, booth A39.

Information provided by Synova.