大型相控阵雷达天线阵面制造技术研究

【作者】 孙刚；

【导师】 王益祥； 冯杏梅；

【作者基本信息】 南京理工大学 ， 机械工程， 2010， 硕士

【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、推广更多还原

【Abstract】 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.更多还原