Components subjected to extreme temperatures in aerospace
In the aerospace industry, certain mechanical parts—particularly in propulsion systems, turbomachinery, and afterburner modules—are subjected to extreme temperatures, sometimes exceeding 1,000°C. Under these conditions, the only way to preserve the integrity of the materials is to actively cool critical components using internal microchannels or cooling holes.
These holes, sometimes invisible to the naked eye, allow air to escape to the surface of the component to form a protective thermal film, reducing the effective temperature perceived by the base material. This process is essential for extending the life of parts, improving thermal performance, and ensuring the safety of equipment in flight.
But to be effective, these cooling holes must be extremely small in diameter (often between 0.1 and 0.3 mm), perfectly positioned, and oriented at a precise angle. Their quality directly affects cooling efficiency. Any burrs, variations in diameter, or angular deviations can alter airflow and reduce system performance.
Micro-drilling by electroerosion: an essential technology for cooling holes
Given these requirements, micro-drilling by electroerosion is the ideal solution. Unlike mechanical drilling, it generates no torque or axial force, and therefore does not risk deforming the part or introducing internal stresses. It allows very fine holes to be drilled in ultra-hard materials (nickel alloys, cobalt, Inconel, etc.), with excellent repeatability and without burrs.
Thanks to high-precision machines, the electrodes can be oriented at predefined angles, allowing oblique, crossed, or directional holes to be created with remarkable consistency. Micro-drilling by electrical discharge machining also allows great depths to be reached (several dozen times the diameter of the hole), which is essential in the thick walls of propulsion parts.
At the end of the process, specific dimensional checks are carried out using high-resolution optical microscopy or probes. Measurement reports include the average diameter, angle, circularity, perpendicularity, and exact location of the hole to ensure complete traceability and strict compliance with specifications.
Mecasoft: specialist in micro-drilling for cooling holes in aerospace components
For over 20 years, Mecasoft has been working with clients in the aerospace industry to produce complex cooling holes in turbine components, injectors, and thermal modules. This includes development and prototyping, mass-produced parts, or simply to relieve pressure or compensate for undercapacity among its clients. Thanks to its micro-drilling equipment, Mecasoft is able to produce series of very small diameter holes with perfect angular alignment and consistent precision.
The machines used are programmable along multiple trajectories, enabling the creation of networks of holes distributed across curved or hard-to-reach surfaces. The materials machined include refractory superalloys, without surface degradation. Each drilling operation is validated by rigorous testing and documented in a dimensional report guaranteeing compliance with customer specifications.
Mecasoft draws on its expertise in precision micromechanics, hard material machining, and optical 3D metrology to guarantee reliable, traceable, and reproducible results. Whether for prototypes or small series with high added value, Mecasoft supports its industrial partners in projects where precision is a matter of performance—or even safety.
