Laser assisted machining of hard and brittle materials in aerospace fields: A review

Hard and brittle materials are increasingly employed in the aerospace fields owing to their exceptional properties, including high wear and corrosion resistance, superior radiation tolerance, and excellent anti-thermal shock performance under extreme temperatures. However, their inherent high hardness presents significant challenges for conventional mechanical machining, often resulting in excessive cutting forces and severe tool wear. Simultaneously, their brittleness induces the surface/subsurface damage of aerospace components. Laser Assisted Machining (LAM) has emerged as a promising advanced manufacturing technology that enables high-efficiency, low-damage machining of hard and brittle materials. Nevertheless, current research on LAM lacks a comprehensive and in-depth analysis. To address this gap, the study investigates the material removal mechanism by simulation and experiments, with particular attention to laser-material interactions. Then, this review systematically analyzes various mechanical machining processes, including laser assisted turning, laser assisted milling, laser assisted grinding, and laser-ultrasonic assisted machining. Moreover, the machining process optimization of LAM is also analyzed to reduce the machining damage, focusing on key influencing factors specific to hard and brittle materials. Finally, the prospects and future directions of LAM technology are discussed, which offer the theoretical foundation and technical roadmap for its application in high-performance equipment of aerospace fields.