Laser beam micro-milling of nickel alloy: dimensional variations and RSM optimization of laser parameters

Micro-channels are considered as the integral part of several engineering devices such as micro-channel heat exchangers, micro-coolers, micro-pulsating heat pipes and micro-channels used in gas turbine blades for aerospace applications. In such applications, a fluid flow is required to pass through certain micro-passages such as micro-grooves and micro-channels. The fluid flow characteristics (flow rate, turbulence, pressure drop and fluid dynamics) are mainly established based on the size and accuracy of micro-passages. Variations (oversizing and undersizing) in micro-passage's geometry directly affect the fluid flow characteristics. In this study, the micro-channels of several sizes are fabricated in well-known aerospace nickel alloy (Inconel 718) through laser beam micro-milling. The variations in geometrical characteristics of different-sized micro-channels are studied under the influences of different parameters of Nd:YAG laser. In order to have a minimum variation in the machined geometries of each size of micro-channel, the multi-objective optimization of laser parameters has been carried out utilizing the response surface methodology approach. The objective was set to achieve the targeted top widths and depths of micro-channels with minimum degree of taperness associated with the micro-channel's sidewalls. The optimized sets of laser parameters proposed for each size of micro-channel can be used to fabricate the micro-channels in Inconel 718 with minimum amount of geometrical variations.