CN110572996A - composite all-welded aluminum honeycomb core waveguide window and production process thereof - Google Patents
composite all-welded aluminum honeycomb core waveguide window and production process thereof Download PDFInfo
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- CN110572996A CN110572996A CN201910677256.9A CN201910677256A CN110572996A CN 110572996 A CN110572996 A CN 110572996A CN 201910677256 A CN201910677256 A CN 201910677256A CN 110572996 A CN110572996 A CN 110572996A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P1/00—Auxiliary devices
- H01P1/08—Dielectric windows
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0001—Rooms or chambers
- H05K9/0005—Shielded windows
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0007—Casings
- H05K9/0041—Ventilation panels having provisions for screening
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Abstract
the invention discloses a composite all-welded aluminum honeycomb core waveguide window which comprises a flange plate, wherein two honeycomb cores are arranged at the upper end of the flange plate; a production process of a composite all-welded aluminum honeycomb core waveguide window comprises the following steps: and S1, calculating the waveguide depth according to the electromagnetic field shielding performance requirement required by the customer. Aiming at the shielding effectiveness requirements of electric and magnetic fields of different independent frequency bands or high and low frequency bands, the invention selects and uses the welding aluminum honeycomb cores with different waveguide depths, side lengths and thicknesses; the side length and the distance of the hexagon of the punching plate can be adjusted according to different shielding efficiencies; aiming at different shielding properties, the middle punching plate can be replaced by materials such as low-carbon steel, copper and the like; the number of the interlayers of the middle punching plate is determined according to different shielding requirements; the shielding effectiveness of the high-frequency and low-frequency magnetic fields of the whole product is obviously improved, the application range of the product is wider and wider, and the electromagnetic shielding effectiveness of equipment and a shielding room is solved and satisfied, and the ventilation and heat dissipation effects are also solved.
Description
Technical Field
the invention relates to the technical field of electromagnetic protection, in particular to a composite all-welded aluminum honeycomb core waveguide window and a production process thereof.
background
In order to keep the air inside the shielding room or the machine room circulating, a window needs to be opened on the shielding room or the shielding shell, the window is a main channel for shielding the exchange between the air inside the room and the outside, and can effectively stop the passing through of electromagnetic waves, and the window is called a waveguide window. The ventilation waveguide window is a cut-off waveguide bundle composed of a plurality of small cut-off waveguides, and the cross section of the ventilation waveguide window is hexagonal. The cross-sectional form of the ventilation cut-off waveguide window is generally as follows: circular, square, and hexagonal. Square and hexagonal waveguides are advantageous for isolation of electromagnetic waves because they allow fewer propagating modes than circular waveguides; the channel area of the hexagonal waveguide is larger than that of the square waveguide window under the condition of equal insertion attenuation capacity. Hexagonal ventilation waveguide windows are often used for ventilation waveguide windows. The installation form thereof has two kinds: bolt crimping and welding.
The waveguide window shield faces the electric and magnetic field shields of different frequency bands, different metal shielding materials are selected for different shielding fields, high-permeability materials are selected for low-frequency magnetic field shielding, and high-conductivity metal materials are selected for high-frequency magnetic field shielding. When the electric field and the magnetic field are simultaneously shielded, a material with high conductivity is generally selected. However, in the actual occasions with high electric and magnetic field shielding requirements, a single type of metal material cannot meet the requirements, and waveguide windows made of a single material, such as aluminum or steel, are selected in the market at present.
the aluminum waveguide window uses the aluminum honeycomb core, and has the outstanding problems that the honeycomb core mostly adopts an adhesive honeycomb structure, the shielding efficiency is poor, the service life is short, and the application occasion is limited; the steel honeycomb core has poor corrosion resistance, is easy to rust and oxidize, and influences the service life. For the aluminum honeycomb core waveguide window, because aluminum is a material with high conductivity and has the effect of shielding an electric field and a high-frequency magnetic field, welding of the aluminum honeycomb core waveguide window is difficult to achieve due to the characteristic of easy oxidation of the aluminum, and the application with high shielding requirements is difficult to meet customer requirements.
If the problems of welding between aluminum honeycomb cores and metallurgical connection between the aluminum honeycomb cores and a window frame can be solved, and high-permeability materials such as iron and low-carbon steel are added, the problems that shielding efficiency is reduced due to non-metallurgical connection between the aluminum honeycomb cores are solved, electrochemical corrosion resistance of products is improved, shielding efficiency of the products with high integrity and low-frequency electromagnetic fields is obviously improved, application range of the products is wider and wider, but in the occasions with actual high-electromagnetic-field shielding requirements, a single type of metal material cannot meet the requirements, so that the problems are solved by selecting the metal containing the high-permeability material and the metal containing the high conductivity, and the composite all-welded aluminum honeycomb core waveguide window and the production process thereof are provided for solving the problems.
disclosure of Invention
The invention aims to solve the defects in the prior art and provides a composite all-welded aluminum honeycomb core waveguide window.
In order to achieve the purpose, the invention adopts the following technical scheme:
The utility model provides a compound all-welded aluminium honeycomb core waveguide window, includes the ring flange, the upper end of ring flange is equipped with two honeycomb cores, is equipped with corrosion resistant plate between two honeycomb cores, and skin aluminum plate is gone up in the upper end welding of one of them honeycomb core, and the lower extreme welding of another honeycomb core is on the ring flange, all be equipped with the opening on going up skin aluminum plate and the ring flange, equidistant dashing is equipped with a plurality of hexagon through-holes on the corrosion resistant plate, the honeycomb core be fixed with first window frame and second window frame all around, and first window frame and second window frame correspond each other.
preferably, the first window frame and the second window frame are welded in a seamless mode, the first window frame, the second window frame and the flange plate are welded in a seamless mode, and the first window frame, the second window frame and the upper skin aluminum plate are welded in a seamless mode.
Preferably, the area of the flange is larger than the area of the honeycomb core.
The invention also provides a production process of the composite all-welded aluminum honeycomb core waveguide window, which comprises the following steps:
S1, calculating the waveguide depth according to the electromagnetic field shielding performance requirements required by customers, selecting the side length of the honeycomb core, the height of the honeycomb core and the thickness of an aluminum foil of the aluminum honeycomb core, wherein the selected aluminum foil is an aluminum composite material, and compounding brazing filler metal on the surface of the aluminum foil;
S2, according to the requirements of the regular hexagon metal honeycomb core multi-cell structure, performing coil material cutting according to the required height of the aluminum foil, calculating according to the plate area required by a customer, and cutting a certain number of aluminum foil strips;
s3, manufacturing the cut aluminum foil into a corrugated structure by a rolling method;
S4, cleaning and drying the cut corrugated aluminum foil surface;
S5, arranging the semi-regular hexagonal honeycomb strips in parallel according to a rule, and spot-welding to simply and relatively fix the semi-regular hexagonal honeycomb strips into a regular hexagonal metal honeycomb core;
s6, respectively spraying soldering flux on the surfaces of an upper skin aluminum plate and a flange plate which are made of a plurality of layers of composite materials compounded with brazing filler metal and are ready to be connected with a honeycomb core, and simultaneously spraying soldering flux on the woven regular hexagonal aluminum honeycomb core; assembling an outer skin aluminum plate and a flange plate on the upper side and the lower side of the regular hexagonal aluminum honeycomb core to form a hexagonal metal aluminum honeycomb plate structure, and clamping and fixing by using a tool clamp;
s7, placing the assembled hexagonal aluminum honeycomb structure into a brazing furnace for brazing, and fastening by using a tool before welding to ensure that the honeycomb core is connected with the honeycomb core, and the honeycomb core is connected with the upper skin aluminum plate and the flange plate by 100% wires;
s8, cooling and aging the welded aluminum honeycomb panel;
s9, cutting the welded aluminum honeycomb plate into two honeycomb cores with the same height from the middle position of the honeycomb core, wherein the cut honeycomb core is provided with two fittings of an aluminum plate of the skin and a flange plate;
s10, taking a stainless steel plate, punching the stainless steel plate to form a hexagonal pattern, wherein the area of the stainless steel plate is consistent with the sectional area of the honeycomb core, the side length and the interval of a hexagonal hole are calculated according to the actual shielding effectiveness requirement, the area of the punched part corresponds to the area of a milled window, and the punched hole is deburred;
S11, placing the welded honeycomb plate fitting with the flange on the bottommost layer, placing a punched hexagonal stainless steel plate above the welded honeycomb plate fitting with the flange, placing the honeycomb plate fitting with the upper skin above the punched hexagonal stainless steel plate, aligning the openings of the three fittings, and tightly pressing the three fittings by using tooling to enable the honeycomb core and the stainless steel plate to be in tight fit;
S12, wrapping the peripheries of the three pressing fittings by using a first window frame and a second window frame which are the same in size and size, then carrying out seamless welding on the first window frame and the second window frame and the connecting parts of the first window frame, the second window frame and the flange plate, and carrying out seamless welding on the connecting parts of the first window frame, the second window frame and the upper skin aluminum plate;
s13, polishing the surface after welding;
s14, in order to ensure 100% conduction of the stainless steel plate and the honeycomb core, coating shielding glue on the connection part of the stainless steel plate and the honeycomb core according to the requirement;
and S15, finally spraying the conductive paint according to the color requirements of customers.
preferably, the thickness of the stainless steel plate 7 in S10 is 0.5 to 5 mm.
in the invention, all the connection points and connection lines between the honeycombs and the connection lines between the honeycomb core and the flange plate and between the honeycomb core and the upper skin aluminum plate are welded in a seamless manner, so that the shielding efficiency of the product is ensured; in addition, the flange plate and the window frames, the two window frames and the window frame and the upper skin aluminum plate are also welded in a seamless mode, and connecting lines and connecting surfaces of the connecting parts are all in metal metallurgical connection, so that the shielding effect is enhanced; aiming at the requirements of different independent frequency bands or high-low frequency band electromagnetic field shielding effectiveness, welding aluminum honeycomb cores with different waveguide depths, different side lengths and different thicknesses are selected; the side length and the distance of the hexagon of the punching plate can be adjusted according to different shielding efficiencies; aiming at the materials with different shielding performances and the replaceable middle punching plate, for example, the materials can be replaced by low-carbon steel, copper and the like; the number of the interlayers of the middle punching plate is determined according to different shielding requirements; the shielding effectiveness of the high and low frequency magnetic fields of the whole product is obviously improved, and the application range of the product is wider and wider; if the shielding shell is a steel plate, the steel-aluminum composite plate is connected with the flange plate, the problem of dissimilar metal connection between the shell of the pure aluminum waveguide window and the steel connector is solved, the shielding characteristics of the waveguide window can be flexibly changed by adjusting the multiple combination modes according to different shielding performance requirements, the shielding effect is finally adjusted, and the effects of ventilation and heat dissipation are solved and met by the electromagnetic shielding effectiveness of equipment and a shielding room.
drawings
FIG. 1 is a schematic view of an installation structure of a composite all-welded aluminum honeycomb core waveguide window according to the present invention;
FIG. 2 is a schematic structural view of a composite all-welded aluminum honeycomb core waveguide window according to the present invention;
FIG. 3 is a cross-sectional view of a composite all-welded aluminum honeycomb core waveguide window according to the present invention;
FIG. 4 is a schematic structural view of a stainless steel plate of a composite all-welded aluminum honeycomb core waveguide window according to the present invention;
FIG. 5 is a schematic view of a flange structure of a composite all-welded aluminum honeycomb core waveguide window according to the present invention;
FIG. 6 is a schematic view of an installation structure of a composite all-welded aluminum honeycomb core waveguide window scheme 2 waveguide window according to the present invention;
FIG. 7 is a cross-sectional view of a composite all-welded aluminum honeycomb core waveguide window scheme 2 waveguide window in accordance with the present invention;
FIG. 8 is a schematic view of a honeycomb core wire penetration structure of a composite all-welded aluminum honeycomb core waveguide window of embodiment 2 in accordance with the present invention;
FIG. 9 is a schematic view of the installation structure of a composite all-welded aluminum honeycomb core waveguide window scheme 3 waveguide window according to the present invention;
FIG. 10 is a cross-sectional view of a composite all-welded aluminum honeycomb core waveguide window scheme 3 waveguide window according to the present invention;
fig. 11 is an enlarged view of a structure at a position a of a composite all-welded aluminum honeycomb core waveguide window scheme 2 according to the present invention.
In the figure: 1, covering aluminum plate, 2 openings, 3 first window frames, 4 honeycomb cores, 5 second window frames, 6 flange plates and 7 stainless steel plates.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
Scheme 1
referring to fig. 1, 2, 3, 4 and 5, the steps of a production process of a composite all-welded aluminum honeycomb core waveguide window are as follows:
s1, calculating the waveguide depth according to the electromagnetic field shielding performance requirements required by customers, selecting the side length of the honeycomb core 4, the height of the honeycomb core 4 and the aluminum foil thickness of the aluminum honeycomb core, wherein the selected aluminum foil is an aluminum composite material, and compounding brazing filler metal on the surface of the aluminum foil;
s2, according to the requirements of the regular hexagon metal honeycomb core multi-cell structure, performing coil material cutting according to the required height of the aluminum foil, calculating according to the plate area required by a customer, and cutting a certain number of aluminum foil strips;
s3, manufacturing the cut aluminum foil into a corrugated structure by a rolling method;
s4, cleaning and drying the cut corrugated aluminum foil surface;
s5, arranging the semi-regular hexagonal honeycomb strips in parallel according to a rule, and spot-welding to simply and relatively fix the semi-regular hexagonal honeycomb strips into a regular hexagonal metal honeycomb core;
s6, opening 2 on an upper skin aluminum plate 1 and a flange plate 6 which are made of a multi-layer composite material compounded with brazing filler metal, spraying brazing flux on the upper skin, the lower skin and one surface to be connected with a honeycomb core 4 respectively, and spraying brazing flux on the woven regular hexagonal aluminum honeycomb core 4; assembling an upper skin aluminum plate 1 and a flange plate 6 on the upper side and the lower side of the regular hexagonal aluminum honeycomb core to form a hexagonal metal aluminum honeycomb plate structure, and clamping and fixing by using a tool clamp;
s7, placing the assembled hexagonal aluminum honeycomb structure into a brazing furnace for brazing, and fastening by using a tool before welding to ensure that the welding between the honeycomb core 4 and the honeycomb core 4, and the welding between the honeycomb core 4 and the upper skin aluminum plate 1 and the flange plate 6 are 100% line connection;
s8, cooling and aging the welded aluminum honeycomb panel;
S9, cutting the welded aluminum honeycomb plate into two honeycomb cores 4 with the same height from the middle position of the honeycomb core, wherein the cut honeycomb cores 4 are provided with two accessories of a skin aluminum plate 1 and a flange plate 6;
S10, taking a stainless steel plate 7, punching the stainless steel plate 7 to form a hexagonal pattern, calculating the side length and the interval of a hexagonal hole according to the actual shielding effectiveness requirement, wherein the area of the punched part corresponds to the area of a milled window, and punching the hole to remove burrs, wherein the area of the stainless steel plate is consistent with the sectional area of the honeycomb core 4;
s11, placing the welded honeycomb plate fitting with the flange and the window on the bottommost layer, placing the punched hexagonal stainless steel plate 7 above the welded honeycomb plate fitting, placing the honeycomb plate fitting with the window and the skin above the honeycomb plate fitting, aligning the openings 2 of the three fittings, and tightly pressing the three fittings by using tooling to ensure that the honeycomb core 4 is in tight fit with the stainless steel plate 7;
s12, wrapping the three pressed fittings with two first window frames 3 and two second window frames 5 with the same size, then performing seamless welding on the first window frames 3 and the second window frames 5 and the connecting parts of the first window frames 3 and the second window frames 5 and the flange 6, and performing seamless welding on the connecting parts of the first window frames 3 and the second window frames 5 and the upper skin aluminum plate 1;
s13, polishing the surface after welding;
S14, in order to ensure 100% conduction of the stainless steel plate and the honeycomb core, coating shielding glue on the connection part of the stainless steel plate and the honeycomb core according to the requirement;
and S15, finally spraying the conductive paint according to the color requirements of customers.
Scheme 2
Referring to fig. 4, 6, 7, 8 and 11, the steps of a production process of the composite all-welded aluminum honeycomb core waveguide window are as follows:
s1, calculating the waveguide depth according to the electromagnetic field shielding performance requirements required by customers, selecting the side length of the honeycomb core 4, the height of the honeycomb core 4 and the aluminum foil thickness of the aluminum honeycomb core, wherein the selected aluminum foil is an aluminum composite material, and compounding brazing filler metal on the surface of the aluminum foil;
s2, according to the requirements of the regular hexagon metal honeycomb core multi-cell structure, performing coil material cutting according to the required height of the aluminum foil, calculating according to the plate area required by a customer, and cutting a certain number of aluminum foil strips;
s3, stacking the cut aluminum foils, cutting micropores with the diameter of 1-1.5mm at the calculated position of the aluminum foils, and perforating at the same horizontal line at the midpoint of the three corrugated edges to be pressed;
s4, manufacturing the cut aluminum foil with the punched holes into a corrugated structure by a rolling method;
s5, cleaning and drying the cut corrugated aluminum foil surface;
s6, after arranging the semi-regular hexagonal honeycomb strips side by side, selecting stainless steel wires with the diameter smaller than 1mm to respectively penetrate through the honeycomb core 4 with drilled holes from three corrugated sides, so that the stainless steel wires form a net structure on a horizontal line and are mutually communicated, connected and fixed, then performing spot welding to simply and relatively fix the net structure into a regular hexagonal metal honeycomb core, and tensioning, connecting and fixing the parts of the penetrated stainless steel wires extending out of the honeycomb core 4 in one direction to ensure that the crossed parts of the stainless steel wires can be connected together;
s7, after an opening 2 is formed in an upper skin and a lower skin which are made of a multi-layer composite material compounded with brazing filler metal, respectively spraying brazing flux on the upper skin, the lower skin and one surface to be connected with a honeycomb core 4, and meanwhile, spraying brazing flux on the honeycomb core 4 which is woven with a stainless steel mesh structure; assembling an upper cover plate on the upper side and the lower side of the regular hexagonal metal honeycomb core to form a hexagonal metal honeycomb plate structure, and clamping and fixing by using a jig;
s8, placing the assembled hexagonal metal honeycomb structure into a brazing furnace for brazing, and fastening by using a tool before welding to ensure that the connecting line between the honeycomb core 4 and the honeycomb core 4, and the connecting line and the connecting surface between the honeycomb core 4 and the upper and lower skins are in 100% metallurgical connection;
s9, cooling and aging the welded honeycomb plate;
S10, taking one welded aluminum honeycomb plate and manufacturing another welded aluminum honeycomb plate, wherein the area of the flange and the upper skin of the second welded aluminum honeycomb plate is consistent with the area of the upper skin of the first windowed aluminum honeycomb plate.
S11, stacking the two windowed honeycomb aluminum plates together, placing a stainless steel plate 7 with hexagonal punched holes in the middle of the two windowed honeycomb aluminum plates with the flange plate with a large area at the lowest part, and placing the upper windowed honeycomb aluminum plate and the lower windowed honeycomb aluminum plate in a staggered manner as much as possible in the placing process, wherein the flange plate with a large area is positioned at the lowest part;
S12, performing seamless welding on the connecting parts of the two welded aluminum honeycomb panels, and simultaneously ensuring that the stainless steel plate 7 or copper plate with the hexagonal punched hole arranged in the middle is tightly matched with the two connecting window frames;
s13, wrapping the periphery of the welded aluminum honeycomb panel by using a first window frame 3 and a second window frame 5 which are identical in size, then performing seamless welding on the first window frame 3 and the second window frame 5 and the connecting parts of the first window frame 3 and the second window frame 5 and the flange 6, and performing seamless welding on the connecting parts of the first window frame 3 and the second window frame 5 and the upper skin aluminum plate 1;
s14, polishing the surface after welding;
s15, coating shielding glue on the lapping part between the stainless steel wires according to the requirement in order to ensure 100% conduction between the stainless steel wires;
And S16, finally spraying the conductive paint according to the color requirements of customers.
in the scheme 2, the number of layers of the stainless steel net is adjusted according to different electromagnetic field shielding effectiveness requirements.
referring to fig. 9 and 10, a window can be independently selected for use as a waveguide window.
In addition, the 3 technical schemes can form independent waveguide window structures.
electromagnetic shielding techniques are classified into electric field shielding, magnetic field shielding, and electromagnetic field shielding. Except that adjusting its shielding effect through adjustment honeycomb core length of side and waveguide depth, different field shielding technical essence are different, and the shielding material that uses also has a difference, and when shielding effect required is very high, the individual layer is shielded often hardly in order to satisfy the requirement, can adopt multilayer combination shielding structure, adopts diamagnetic material at the shielding outer layer, and the inlayer adopts strong magnetic material's combination shielding. When the shielding layer is a multilayer shielding formed by ferromagnetic materials and conductive materials, no gap is formed between the shielding layers, and in addition, in order to maintain the integrity of the shielding body and ensure better shielding effectiveness at the transition part, a welding method can be adopted to maintain the continuity of the contact surface. The invention aims at the shielding effectiveness requirements of electric and magnetic fields of different independent frequency bands or high and low frequency bands, selects aluminum honeycomb cores with different waveguide depths, different side lengths and different thicknesses, can adjust the side lengths and the distances of hexagons of the punching plates and the number of intermediate interlayers according to different shielding effectiveness, and can adjust the shielding effectiveness by changing the materials selected by the intermediate interlayers: can be made of ferromagnetic material, such as iron, steel and other metals, and can also be made of diamagnetic material, such as copper and other metals. Different combination forms can flexibly adjust the shielding effectiveness of the high-frequency and low-frequency magnetic fields of the whole product, so that the application range of the product is wider and wider.
the above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be able to cover the technical scope of the present invention and the equivalent alternatives or modifications according to the technical solution and the inventive concept of the present invention within the technical scope of the present invention.
Claims (5)
1. The utility model provides a compound all-welded aluminium honeycomb core waveguide window, includes ring flange (6), its characterized in that: the upper end of ring flange (6) is equipped with two honeycomb cores (4), is equipped with corrosion resistant plate (7) between two honeycomb cores (4), and the upper end welding of one of them honeycomb core (4) has covering aluminum plate (1), and the lower extreme welding of another honeycomb core (4) is on ring flange (6), it all is equipped with opening 2 on covering aluminum plate (1) and ring flange (6) to go up, equidistant dashing of corrosion resistant plate (7) is equipped with a plurality of hexagon through-holes, be fixed with first window frame (3) and second window frame (5) around honeycomb core (4), and first window frame (3) and second window frame (5) correspond each other.
2. A composite all-welded aluminium honeycomb core waveguide window according to claim 1, characterized in that there is no seam welded between the first sash (3) and the second sash (5), between the first sash (3), the second sash (5) and the flange plate (6), and between the first sash (3), the second sash (5) and the upper skin aluminium panel (1).
3. A composite all-welded aluminium honeycomb core waveguide window according to claim 1, characterised in that the flange (6) has an area larger than the area of the honeycomb core (4).
4. a production process of a composite all-welded aluminum honeycomb core waveguide window is characterized by comprising the following steps:
s1, calculating the waveguide depth according to the electromagnetic field shielding performance requirements required by customers, selecting the side length of the honeycomb core (4), the height of the honeycomb core (4) and the aluminum foil thickness of the aluminum honeycomb core, wherein the selected aluminum foil is an aluminum composite material, and compounding brazing filler metal on the surface of the aluminum foil;
s2, according to the requirements of the regular hexagon metal honeycomb core multi-cell structure, performing coil material cutting according to the required height of the aluminum foil, calculating according to the plate area required by a customer, and cutting a certain number of aluminum foil strips;
s3, manufacturing the cut aluminum foil into a corrugated structure by a rolling method;
s4, cleaning and drying the cut corrugated aluminum foil surface;
s5, arranging the semi-regular hexagonal honeycomb strips in parallel according to a rule, and spot-welding to simply and relatively fix the semi-regular hexagonal honeycomb strips into a regular hexagonal metal honeycomb core;
S6, respectively spraying soldering flux on one surfaces of an upper skin aluminum plate (1) and a flange plate (6) which are made of a plurality of layers of composite materials compounded with brazing filler metal and are ready to be connected with a honeycomb core (4), and simultaneously spraying soldering flux on the woven regular hexagonal aluminum honeycomb core (4); assembling an outer skin aluminum plate (1) and a flange plate (6) on the upper side and the lower side of the regular hexagonal aluminum honeycomb core to form a hexagonal metal aluminum honeycomb plate structure, and clamping and fixing by using a tool clamp;
s7, placing the assembled hexagonal aluminum honeycomb structure into a brazing furnace for brazing, and fastening by using a tool before welding to ensure that the honeycomb core (4) is connected with the honeycomb core (4), and the honeycomb core (4) is connected with the upper skin aluminum plate (1) and the flange plate (6) by 100% of lines;
S8, cooling and aging the welded aluminum honeycomb panel;
s9, cutting the welded aluminum honeycomb plate into two honeycomb cores (4) with the same height from the middle position of the honeycomb core, wherein the cut honeycomb cores (4) are provided with two accessories of a skin aluminum plate (1) and a flange plate (6);
s10, taking a stainless steel plate (7), wherein the area of the stainless steel plate is consistent with the sectional area of the honeycomb core (4), punching holes on the surface of the stainless steel plate (7) to form a hexagonal pattern, calculating the side length and the interval of a hexagonal hole according to the actual shielding effectiveness requirement, and punching holes to remove burrs, wherein the area of the punched part corresponds to the area of a milled window;
s11, placing the welded honeycomb plate fitting with the flange on the bottommost layer, placing a punched hexagonal stainless steel plate (7) above the welded honeycomb plate fitting with the flange, placing the honeycomb plate fitting with the upper skin above the punched hexagonal stainless steel plate, aligning the openings of the three fittings, and tightly pressing the three fittings by using tooling to enable the honeycomb core (4) and the stainless steel plate (7) to be in tight fit;
s12, wrapping the peripheries of the three pressing fittings by using a first window frame (3) and a second window frame (5) which are the same in size, then carrying out seamless welding on the first window frame (3) and the second window frame (5) and the connecting parts of the first window frame (3), the second window frame (5) and a flange plate (6), and carrying out seamless welding on the connecting parts of the first window frame (3), the second window frame (5) and an upper skin aluminum plate (1);
s13, polishing the surface after welding;
s14, in order to ensure 100% conduction of the stainless steel plate and the honeycomb core, coating shielding glue on the connection part of the stainless steel plate and the honeycomb core according to the requirement;
and S15, finally spraying the conductive paint according to the color requirements of customers.
5. a process for manufacturing a composite all-welded aluminum honeycomb core waveguide window according to claim 4, wherein the thickness of the stainless steel plate (7) in S10 is 0.5-5 mm.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115922008A (en) * | 2023-01-04 | 2023-04-07 | 中国科学院空天信息创新研究院 | Waveguide window welding method and tool applied to space traveling wave tube and waveguide window |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115922008A (en) * | 2023-01-04 | 2023-04-07 | 中国科学院空天信息创新研究院 | Waveguide window welding method and tool applied to space traveling wave tube and waveguide window |
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| CN110572996B (en) | 2021-10-26 |
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