大型相控阵雷达天线阵面制造技术研究
|
摘要
相控阵雷达天线阵面是相控阵雷达系统中的关键设备,通常由许多辐射单元阵列组成,其内部结构紧凑,相关尺寸精度要求很高,结构设计时可以参照国外的一些现有产品,但制造技术必须要靠自己进行摸索,尤其是在国内基础制造业不发达的情况下,制造过程中的许多特殊过程均需要自行组织进行专业攻关。
本课题针对某相控阵雷达的天线阵面制造过程展开,主要研究了天线阵面中反射面板的焊接工艺方法和天线阵面中箱体的铆接工艺方法。
在反射面板的焊接过程中,对比了熔焊与搅拌摩擦焊各自的性能特点,选取了搅拌摩擦焊进行试验,制作等比小样摸索焊接参数,并对其机械性能、宏观、微观组织、硬度、三防性能等进行了一系列的认证,然后进行正式产品的制造,并对正式产品的机械性能、宏观、微观组织、化学成分、晶粒度等进行了再次确认。
在天线阵面箱体的精密铆接过程中,对比了冲击铆接与液压铆接各自的性能特点,自行研发制造液压铆接系统,通过有限元分析和试验样件确认后,应用在正式产品中。
经过实际作业以及雷达使用的实际结果,本课题研究的制造技术是可行和可靠的。目前,搅拌摩擦焊技术目前已推广应用在相控阵雷达组件冷板的二维水道焊接以及航天火箭整流罩的三维焊接中,液压铆接技术也已推广应用在机载相控阵雷达的总装制造过程中。随着课题研究的深入发展,还会有更多新型制造技术被应用在大型相控阵雷达的精密制造领域,仍然需要我们不断的论证、引进、掌握、推广
Phased array antenna is key component in phased array radar system. Usually, it is composed of many radiating arrays as well as features compact structure and high requirements for dimensional accuracy. Foreign products can be referred to during designing, while manufacturing technology must be felt after by oneself. Especially, some special technological processing required to be researched and developed independently under the condition that manufacturing is underdeveloped.
This subject aims at manufacturing process of antenna array of some phased array radar, which researches on welding technology of reflector panel in antenna array and riveting technology of box in antenna array.
By comparing feature of fusion welding with that of stirring friction welding, the latter is selected for reflector panel. Samples of equal ratio are made for research on welding parameters; mechanical performance, macro-structure, micro-structure, hardness, conformal performance are certified and then products are manufactured formally. After that, mechanical performance, macro-structure, micro-structure, chemical composition, crystal degree are recertified.
By comparing feature of impact welding with that of hydraulic welding during riveting box of antenna array precisely, hydraulic riveting system is developed independently and is applied to actual products after analysis of finite element and re-confirmation of test sample.
The research on manufacturing technology in this subject is testified to be feasible and reliable after actual processing and application to radar. Presently, stirring friction welding technology is spread to 2D water-channel welding of cold plate in phased array radar module and 3D welding of cowling on space rocket. Additionally, hydraulic riveting technology is spread to assembly of airborne phased array radar. With progressive development of research on this subject, more new processing technology will be applied to precise manufacture field of large-scale phase array radar which required continuous demonstration, introduction, mastery and spreading.
本课题针对某相控阵雷达的天线阵面制造过程展开,主要研究了天线阵面中反射面板的焊接工艺方法和天线阵面中箱体的铆接工艺方法。
在反射面板的焊接过程中,对比了熔焊与搅拌摩擦焊各自的性能特点,选取了搅拌摩擦焊进行试验,制作等比小样摸索焊接参数,并对其机械性能、宏观、微观组织、硬度、三防性能等进行了一系列的认证,然后进行正式产品的制造,并对正式产品的机械性能、宏观、微观组织、化学成分、晶粒度等进行了再次确认。
在天线阵面箱体的精密铆接过程中,对比了冲击铆接与液压铆接各自的性能特点,自行研发制造液压铆接系统,通过有限元分析和试验样件确认后,应用在正式产品中。
经过实际作业以及雷达使用的实际结果,本课题研究的制造技术是可行和可靠的。目前,搅拌摩擦焊技术目前已推广应用在相控阵雷达组件冷板的二维水道焊接以及航天火箭整流罩的三维焊接中,液压铆接技术也已推广应用在机载相控阵雷达的总装制造过程中。随着课题研究的深入发展,还会有更多新型制造技术被应用在大型相控阵雷达的精密制造领域,仍然需要我们不断的论证、引进、掌握、推广
Phased array antenna is key component in phased array radar system. Usually, it is composed of many radiating arrays as well as features compact structure and high requirements for dimensional accuracy. Foreign products can be referred to during designing, while manufacturing technology must be felt after by oneself. Especially, some special technological processing required to be researched and developed independently under the condition that manufacturing is underdeveloped.
This subject aims at manufacturing process of antenna array of some phased array radar, which researches on welding technology of reflector panel in antenna array and riveting technology of box in antenna array.
By comparing feature of fusion welding with that of stirring friction welding, the latter is selected for reflector panel. Samples of equal ratio are made for research on welding parameters; mechanical performance, macro-structure, micro-structure, hardness, conformal performance are certified and then products are manufactured formally. After that, mechanical performance, macro-structure, micro-structure, chemical composition, crystal degree are recertified.
By comparing feature of impact welding with that of hydraulic welding during riveting box of antenna array precisely, hydraulic riveting system is developed independently and is applied to actual products after analysis of finite element and re-confirmation of test sample.
The research on manufacturing technology in this subject is testified to be feasible and reliable after actual processing and application to radar. Presently, stirring friction welding technology is spread to 2D water-channel welding of cold plate in phased array radar module and 3D welding of cowling on space rocket. Additionally, hydraulic riveting technology is spread to assembly of airborne phased array radar. With progressive development of research on this subject, more new processing technology will be applied to precise manufacture field of large-scale phase array radar which required continuous demonstration, introduction, mastery and spreading.
引文
[1]张光义.现代相控阵雷达系统,国防工业出版社1994
[2]世界地面雷达手册,国防工业出版社2005
[3]电子14所.舰载雷达现状和发展趋势文集(内部参考)2004
[4]电子14所.舰载相控阵雷达技术文集(内部参考)2002
[5]GJB294A-2005铝及铝合金熔焊机械环境2005
[6]刘家发.焊工手册,机械工业出版社2001
[7]宋天虎.焊接手册,机械工业出版社2001
[8]电子14所.铝及铝合金材料摩擦焊应用研究研制总结.2006
[9]Bhadeshia H K D H. Joining of commercial aluminium alloys[A]. Proceedings of International Conference on Aluminium,2003,195-204.
[10]冯杏梅.先进焊接工艺方法在铝合金产品中应用2008
[11]Thomas M W, Nioholas E D, Needham J C, et al. Friction stir welding[P], International Patent Application No. PCT/GB92102203 and Great Britain Patent Application No.9125978.8.1991.
[12]Mishra R S, Ma Z Y. Friction stir welding and processing[R]. Materials Science and Engineering R,2005,50:1-78.
[13]Chao Y J, Qi X, Tang W. Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies[J]. Transactions of the ASME,2003,125:138-145.
[14]关桥,栾国红.搅拌摩擦焊的现状和发展.工程前沿-香山会议文集.2004.12
[15]Thomas M W, Nioholas E D, Smith S D, et al. Friction stir welding-Tool developments[A]. Aluminum 2001—Proceedings of the TMS 2001 Aluminum Automotive and Joining Symposia, TMS,2001, p.213.
[16]任淑荣,马宗义,陈礼清.搅拌摩擦焊接及其加工研究现状与展望[J].材料导报,2007,21(1)：86-92.
[17]栾国红.搅拌摩擦焊在中国的发展[A].2004年全国焊接学术交流会,2004.
[18]刘日明,孙成凯,党青敏等.搅拌摩擦焊工具的研究现状[J].机械设计与制造,2004,4：45-46.
[19]贺永海,张立武.搅拌摩擦焊用搅拌头的研究进展[J].航空制造技术,2005,5：47-51.
[20]Johnsen, Mary Ruth. Friction stir welding shows great promise for joining of difficult-to-weld materials[J]. Welding Journal,2005,76:1-20.
[21]王快社,王文,徐可为.等径弯曲通道变形镁合金的搅拌摩擦焊接[J].航空材 料学报,2007,27(3)：51-54.
[22]张华,林三宝,吴林等.AZ31镁合金搅拌摩擦焊接头焊核区域成型过程及影响因素[J].航空材料学报,2004,24(2)：6-10.
[23]Wang Xunhong, Wang Kuaishe. Microstructure and properties of friction stir butt welded AZ31 magnesium alloy [J]. Materials Science and Engineering A,2006,431: 114-117.
[24]王希靖,达朝炳,李晶等.黄铜H62搅拌摩擦焊接头的微观组织及性能[J].中国有色金属学报,2006,16(5)：775-779.
[25]Chen Y C, Nakata K. Friction stir lap joining aluminum and magnesium alloys[J]. Scripta Materialia,2007,58(6):433-436.
[26]柴鹏,栾国红.搅拌摩擦焊技术的新起点——钢的焊接[J].焊接,2007,2：13-16.
[27]Ling Cui, Hidetoshi Fujii, Nobuhiro Tsujib et al. Friction stir welding of a high carbon steel[J]. Scripta Materialia,2007,56:637-640.
[28]Sato Y S, Yamanoi H, Kokawa H, et al. Microstructural evolution of ultrahigh carbon steel during friction stir welding[J]. Scripta Materialia,2007,57:557-560.
[29]Reynolds A P, Wei Tang, Gnaupel-Herold T, et al. Structure, properties, and residual stress of 304L stainless steel friction stir welds[J]. Scripta Materialia,2003,48: 1289-1294.
[30]常学斌,葛继平,刘书华等.异种铝合金搅拌摩擦焊接接头的微观组织与力学性能[J].理化检验物理分册,2008,44(6)：281-282.
[31]王希靖,达朝炳,李晶等.T2紫铜与H62黄铜异种材料间的搅拌摩擦焊工艺研究[J].兰州理工大学学报,2007,33(1)：29-33.
[32]Miles M P, Melton D W, Nelson T W. Formability of Friction-Stir-Welded Dissimilar-Aluminum-Alloy Sheets[J]. Metallurgical and materials transactions A, 2005,36A:3335-3342.
[33]Peel M J, Steuwer A, Withers P J, et al. Dissimilar Friction Stir Welds in AA5083-AA6082. Part I:Process Parameter Effects on Thermal History and Weld Properties[J]. Metallurgical and materials transactions A,2006,37A:2183-2193.
[34]Peel M J, Steuwer A, Withers P J, et al. Dissimilar Friction Stir Welds in AA5083-AA6082. Part Ⅱ:Process Parameter Effects on Microstructure[J]. Metallurgical and materials transactions A,2006,37A:2195-2206.
[35]Takehiko Watanabe, Hirofumi Takayama, Atsushi Yanagisawa. Joining of aluminum alloy to steel by friction stir welding[J]. Journal of Materials Processing Technology, 2006,178:342-349.
[36]Sato Y S, Urata M, Kokawa H. Parameters Controlling Microstructure and Hardness during Friction-Stir Welding of Precipitation-Hardenable Aluminum Alloy 6063[J]. Metallurgical and Materials Transactions A,2002,33(3):625-635.
[37]Tang W, Guo X, McClure J C,et al. Heat input and temperature distribution in friction stir welding[J]. Journal of Materials Processing & Manufacturing Science, 1998,7(2):163-172.
[38]Kwon Y J, Saito N, Shigematsu I. Friction stir process as a new manufacturing technique of ultrafine grained aluminum alloy[J]. Journal of Materials Science Letters,2002,21(19):1473-1476.
[39]Hashimoto T, Jyogan, S, Nakata K, et al. FSW Joints of High Strength Aluminium Alloy[A]. Proceedings of the First International Symposium on Friction Stir Welding, USA,1999.
[40]Arbegast W J, Hartley P J. Fracture Toughness Evaluations of 2195 Al-Cu-Li Autogenous and Hybrid Friction Stir Welds[A]. Proceedings of the Fifth International Conference on Trends in Welding Research, USA,1998,541-546.
[41]苏晓莉,王快社,周俊杰等.铝合金搅拌摩擦焊接参数对温度场的影响[J].轻合金加工技术,2006,34(2)：40-42.
[42]Hassan K A A, Pragnell P B, Norman A F, et al. Effect of welding parameters on nugget zone microstructure and properties in high-strength aluminium alloy friction stir welds[J]. Science and Technology of Welding and Joining,2003,8(4):257-268.
[43]Su P, Gerlich A, Yamamoto M, et al. Formation and retention of local melting films in AZ91 friction stir spot welds[J]. Journal of Material Science,2007,42: 9954-9965.
[44]柴鹏,栾国红,孙成彬等.旋转速度对6063铝合金搅拌摩擦焊接头力学性能的影响[J].电焊机,2005,35(3)：31-33.
[45]Liu H J, Fujii H, Maeda M, et al. Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy[J]. Journal of Materials Processing Technology,2003,142:692-696.
[46]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].2005,26(12)：35-38.
[47]Milan M T, Bose Filho W W, Tarpani J R. Residual Stress Evaluation of AA2024-T3 Friction Stir Welded Joints[J]. Journal of Materials Engineering and Performance, 2007,16(1):86-92.
[48]Webster P J, Oosterkamp L D, Browne P A, et al. Synchrotron X-ray residual strain scanning of a friction stir weld[J]. Journal of Strain Analysis,2001,36 (1):61-70.
[49]Staron P, Ko?ak M and Williams S. Residual stresses in friction stir welded Al sheets[J]. Physica B,2004,350:491-493.
[50]李亭,史清宇,李红克等.铝合金搅拌摩擦焊接头残余应力分布[J].焊接学报,2007,28(6)：105-108.
[51]张昭,张洪武.搅拌摩擦焊接中材料变形及残余应力分析[J].兵器材料科学与工程,2006,29(3)：61-66.
[52]Reynolds A P, Wei Tang, Gnaupel-Herold T, et al. Structure, properties, and residual stress of 304L stainless steel friction stir welds[J]. Scripta Materialia,2003,48: 1289-1294.
[53]GJB367.2-87军用同心设备通用技术条件环境试验方法1987
[54]GB/T228金属材料室温拉伸实验方法
[55]夏平,刘兰铆接铆钉分布压力的计算现代制造工程2003
[56]HB/Z 223.3-2003通用铆接技术2003
[57]成大先机械设计手册第三版化学工业出版社1994
[58]洪如瑾UGNX4.0高级仿真培训教程清华大学出版社2007
[2]世界地面雷达手册,国防工业出版社2005
[3]电子14所.舰载雷达现状和发展趋势文集(内部参考)2004
[4]电子14所.舰载相控阵雷达技术文集(内部参考)2002
[5]GJB294A-2005铝及铝合金熔焊机械环境2005
[6]刘家发.焊工手册,机械工业出版社2001
[7]宋天虎.焊接手册,机械工业出版社2001
[8]电子14所.铝及铝合金材料摩擦焊应用研究研制总结.2006
[9]Bhadeshia H K D H. Joining of commercial aluminium alloys[A]. Proceedings of International Conference on Aluminium,2003,195-204.
[10]冯杏梅.先进焊接工艺方法在铝合金产品中应用2008
[11]Thomas M W, Nioholas E D, Needham J C, et al. Friction stir welding[P], International Patent Application No. PCT/GB92102203 and Great Britain Patent Application No.9125978.8.1991.
[12]Mishra R S, Ma Z Y. Friction stir welding and processing[R]. Materials Science and Engineering R,2005,50:1-78.
[13]Chao Y J, Qi X, Tang W. Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies[J]. Transactions of the ASME,2003,125:138-145.
[14]关桥,栾国红.搅拌摩擦焊的现状和发展.工程前沿-香山会议文集.2004.12
[15]Thomas M W, Nioholas E D, Smith S D, et al. Friction stir welding-Tool developments[A]. Aluminum 2001—Proceedings of the TMS 2001 Aluminum Automotive and Joining Symposia, TMS,2001, p.213.
[16]任淑荣,马宗义,陈礼清.搅拌摩擦焊接及其加工研究现状与展望[J].材料导报,2007,21(1)：86-92.
[17]栾国红.搅拌摩擦焊在中国的发展[A].2004年全国焊接学术交流会,2004.
[18]刘日明,孙成凯,党青敏等.搅拌摩擦焊工具的研究现状[J].机械设计与制造,2004,4：45-46.
[19]贺永海,张立武.搅拌摩擦焊用搅拌头的研究进展[J].航空制造技术,2005,5：47-51.
[20]Johnsen, Mary Ruth. Friction stir welding shows great promise for joining of difficult-to-weld materials[J]. Welding Journal,2005,76:1-20.
[21]王快社,王文,徐可为.等径弯曲通道变形镁合金的搅拌摩擦焊接[J].航空材 料学报,2007,27(3)：51-54.
[22]张华,林三宝,吴林等.AZ31镁合金搅拌摩擦焊接头焊核区域成型过程及影响因素[J].航空材料学报,2004,24(2)：6-10.
[23]Wang Xunhong, Wang Kuaishe. Microstructure and properties of friction stir butt welded AZ31 magnesium alloy [J]. Materials Science and Engineering A,2006,431: 114-117.
[24]王希靖,达朝炳,李晶等.黄铜H62搅拌摩擦焊接头的微观组织及性能[J].中国有色金属学报,2006,16(5)：775-779.
[25]Chen Y C, Nakata K. Friction stir lap joining aluminum and magnesium alloys[J]. Scripta Materialia,2007,58(6):433-436.
[26]柴鹏,栾国红.搅拌摩擦焊技术的新起点——钢的焊接[J].焊接,2007,2：13-16.
[27]Ling Cui, Hidetoshi Fujii, Nobuhiro Tsujib et al. Friction stir welding of a high carbon steel[J]. Scripta Materialia,2007,56:637-640.
[28]Sato Y S, Yamanoi H, Kokawa H, et al. Microstructural evolution of ultrahigh carbon steel during friction stir welding[J]. Scripta Materialia,2007,57:557-560.
[29]Reynolds A P, Wei Tang, Gnaupel-Herold T, et al. Structure, properties, and residual stress of 304L stainless steel friction stir welds[J]. Scripta Materialia,2003,48: 1289-1294.
[30]常学斌,葛继平,刘书华等.异种铝合金搅拌摩擦焊接接头的微观组织与力学性能[J].理化检验物理分册,2008,44(6)：281-282.
[31]王希靖,达朝炳,李晶等.T2紫铜与H62黄铜异种材料间的搅拌摩擦焊工艺研究[J].兰州理工大学学报,2007,33(1)：29-33.
[32]Miles M P, Melton D W, Nelson T W. Formability of Friction-Stir-Welded Dissimilar-Aluminum-Alloy Sheets[J]. Metallurgical and materials transactions A, 2005,36A:3335-3342.
[33]Peel M J, Steuwer A, Withers P J, et al. Dissimilar Friction Stir Welds in AA5083-AA6082. Part I:Process Parameter Effects on Thermal History and Weld Properties[J]. Metallurgical and materials transactions A,2006,37A:2183-2193.
[34]Peel M J, Steuwer A, Withers P J, et al. Dissimilar Friction Stir Welds in AA5083-AA6082. Part Ⅱ:Process Parameter Effects on Microstructure[J]. Metallurgical and materials transactions A,2006,37A:2195-2206.
[35]Takehiko Watanabe, Hirofumi Takayama, Atsushi Yanagisawa. Joining of aluminum alloy to steel by friction stir welding[J]. Journal of Materials Processing Technology, 2006,178:342-349.
[36]Sato Y S, Urata M, Kokawa H. Parameters Controlling Microstructure and Hardness during Friction-Stir Welding of Precipitation-Hardenable Aluminum Alloy 6063[J]. Metallurgical and Materials Transactions A,2002,33(3):625-635.
[37]Tang W, Guo X, McClure J C,et al. Heat input and temperature distribution in friction stir welding[J]. Journal of Materials Processing & Manufacturing Science, 1998,7(2):163-172.
[38]Kwon Y J, Saito N, Shigematsu I. Friction stir process as a new manufacturing technique of ultrafine grained aluminum alloy[J]. Journal of Materials Science Letters,2002,21(19):1473-1476.
[39]Hashimoto T, Jyogan, S, Nakata K, et al. FSW Joints of High Strength Aluminium Alloy[A]. Proceedings of the First International Symposium on Friction Stir Welding, USA,1999.
[40]Arbegast W J, Hartley P J. Fracture Toughness Evaluations of 2195 Al-Cu-Li Autogenous and Hybrid Friction Stir Welds[A]. Proceedings of the Fifth International Conference on Trends in Welding Research, USA,1998,541-546.
[41]苏晓莉,王快社,周俊杰等.铝合金搅拌摩擦焊接参数对温度场的影响[J].轻合金加工技术,2006,34(2)：40-42.
[42]Hassan K A A, Pragnell P B, Norman A F, et al. Effect of welding parameters on nugget zone microstructure and properties in high-strength aluminium alloy friction stir welds[J]. Science and Technology of Welding and Joining,2003,8(4):257-268.
[43]Su P, Gerlich A, Yamamoto M, et al. Formation and retention of local melting films in AZ91 friction stir spot welds[J]. Journal of Material Science,2007,42: 9954-9965.
[44]柴鹏,栾国红,孙成彬等.旋转速度对6063铝合金搅拌摩擦焊接头力学性能的影响[J].电焊机,2005,35(3)：31-33.
[45]Liu H J, Fujii H, Maeda M, et al. Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy[J]. Journal of Materials Processing Technology,2003,142:692-696.
[46]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].2005,26(12)：35-38.
[47]Milan M T, Bose Filho W W, Tarpani J R. Residual Stress Evaluation of AA2024-T3 Friction Stir Welded Joints[J]. Journal of Materials Engineering and Performance, 2007,16(1):86-92.
[48]Webster P J, Oosterkamp L D, Browne P A, et al. Synchrotron X-ray residual strain scanning of a friction stir weld[J]. Journal of Strain Analysis,2001,36 (1):61-70.
[49]Staron P, Ko?ak M and Williams S. Residual stresses in friction stir welded Al sheets[J]. Physica B,2004,350:491-493.
[50]李亭,史清宇,李红克等.铝合金搅拌摩擦焊接头残余应力分布[J].焊接学报,2007,28(6)：105-108.
[51]张昭,张洪武.搅拌摩擦焊接中材料变形及残余应力分析[J].兵器材料科学与工程,2006,29(3)：61-66.
[52]Reynolds A P, Wei Tang, Gnaupel-Herold T, et al. Structure, properties, and residual stress of 304L stainless steel friction stir welds[J]. Scripta Materialia,2003,48: 1289-1294.
[53]GJB367.2-87军用同心设备通用技术条件环境试验方法1987
[54]GB/T228金属材料室温拉伸实验方法
[55]夏平,刘兰铆接铆钉分布压力的计算现代制造工程2003
[56]HB/Z 223.3-2003通用铆接技术2003
[57]成大先机械设计手册第三版化学工业出版社1994
[58]洪如瑾UGNX4.0高级仿真培训教程清华大学出版社2007