Preparation method of composite tube shell of high-efficiency high-power helix traveling wave tube

Abstract

The invention relates to the technical field of manufacturing of electronic information type microwave electronic vacuum electronic components, and discloses a preparation method of a composite tube shell of a high-efficiency high-power helix traveling wave tube, which comprises the following steps of: S1, machining a pole shoe blank rod made of a pure iron material and a radiating fin blank cylinder made of a dispersion copper material; s2, a material thermal expansion clamping technology is utilized, the pole shoe blank rod obtained after cold shrinkage nickel plating treatment is loaded into the cooling fin blank cylinder obtained after thermal expansion treatment, and a composite pole shoe blank is formed; and S3, after the normal temperature is recovered, a gold-copper solder wire is installed on the cooling fin blank barrel, and then brazing welding is conducted. Through batch numerical control machining and manufacturing of pole shoe-radiating fin combinations and optimization of material and structural design, production efficiency, size consistency, heat conduction performance and radiating efficiency are remarkably improved, manufacturing cost and deformation risk are reduced, meanwhile, through arc-shaped or circular contact and heat-conducting medium pouring, heat conduction efficiency is improved, temperature gradient is reduced, and the service life of the motor is prolonged. And the technical problems in the traditional method are solved.

Description

Technical Field

[0001] The invention relates to the technical field of manufacturing electronic information microwave vacuum electronic components, and in particular to a method for preparing a high-efficiency and high-power helical traveling wave tube composite tube shell. Background Art

[0002] The traveling wave tube is a commonly used microwave power amplifier. It is widely used in radar, electronic countermeasures, communications, imaging, satellites and other fields due to its high power, wide bandwidth, high efficiency and miniaturization. With the increasing requirements for radar resolution, communication bandwidth and imaging quality, traveling wave tube devices are expanding towards millimeter waves or higher frequency bands and higher power. At present, the heat dissipation technology of high-power helical traveling wave tubes is an urgent problem to be solved in the manufacture and application of traveling wave tubes.

[0003] In the traditional manufacturing process of traveling wave tubes, the combination of pole shoes and heat sinks on the composite tube shell is mostly assembled and connected by brazing one by one. This method not only has low production efficiency, but also easily leads to discreteness in size and quality, making it difficult to meet the requirements of high-power applications for device consistency and reliability. In addition, although the process technology used in the traditional method has certain thermal conductivity, it is easy to cause heat accumulation in high-power applications, affecting device performance and service life. The mechanical strength of the thermal conductive transition material oxygen-free copper is limited and it is easy to deform in high-temperature environments, further limiting the production control, reliability and long-term stability of the device.

[0004] In order to improve the thermal conductivity and structural strength of the traveling wave tube, researchers have tried to introduce new materials and new structures in the design of the pole shoes and heat sinks. For example, by designing the heat sink as a ring structure and using a stronger dispersed copper material, its heat dissipation capacity and anti-deformation performance can be enhanced. In addition, the use of CNC machining to manufacture the pole shoe and heat sink combination can not only improve production efficiency, but also significantly improve the dimensional consistency and manufacturing accuracy of the product.

[0005] Although these improvements have alleviated some of the problems in traditional technologies to a certain extent, they have not completely solved the problems of poor thermal conductivity and heat dissipation efficiency, low manufacturing precision and consistency, complex production process, and high cost. At the same time, the traditional thermal path design is unreasonable, the heat conduction path is long, and the temperature gradient is large, which affects the overall heat dissipation effect and device performance.

[0006] Therefore, the present invention proposes a method for preparing a high-efficiency and high-power helical traveling wave tube composite tube shell. Summary of the invention

[0007] In view of the shortcomings of the prior art, the present invention provides a method for preparing a high-efficiency and high-power helical traveling wave tube composite tube shell, which solves the problems of low heat dissipation efficiency, poor manufacturing accuracy and consistency, low production efficiency and large temperature gradient of the heat conduction path of the traveling wave tube in high-power and high-frequency applications.

[0008] To achieve the above objectives, the present invention is implemented through the following technical solutions: A method for preparing a high-efficiency and high-power helical traveling wave tube composite shell, comprising the following steps:

[0009] S1. Mechanically process the pole shoe blank rod made of pure iron and the heat sink blank tube made of dispersed copper;

[0010] S2. Using the material thermal expansion clamping technology, the cold-shrink nickel-plated pole shoe blank rod is loaded into the heat sink blank tube after thermal expansion treatment to form a composite pole shoe blank;

[0011] S3, after returning to normal temperature, inserting gold-copper solder wire into the heat sink blank tube and then performing brazing welding;

[0012] S4, performing nickel plating and sintering treatment on the entire surface of the composite pole piece;

[0013] S5. Classify the composite pole shoes according to the outer diameter tolerance band using radial dimension automatic screening equipment;

[0014] S6, assembling the composite pole piece, the flat composite pole piece, the connecting ring, the half pole piece, and the energy transmission head through the tube shell welding mandrel and brazing and welding them into a composite tube shell blank;

[0015] S7, the composite tube shell blank is loaded into the matching machine processing tooling and fixed, the composite tube shell core rod is firstly processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method;

[0016] S8. Complete the assembly of the tube core according to the high-frequency circuit assembly process and the tube core welding process.

[0017] Preferably, in step S1, the pole shoe blank rod needs to be subjected to surface nickel plating and sintering treatment.

[0018] Preferably, the step S3 specifically includes the following steps:

[0019] S3.1. Pre-process a solder groove on the heat sink blank tube;

[0020] S3.2. Place the gold-copper solder wire into the solder groove of the heat sink blank tube, and the solder wire is evenly distributed and fully in contact with the parts to be welded;

[0021] S3.3, sending the composite pole shoe blank assembled with solder wire into a hydrogen furnace for brazing welding;

[0022] S3.4. After brazing is completed, take out the welded composite pole shoe blank from the hydrogen furnace, cool it to room temperature, check the welding quality, and obtain the composite pole shoe blank.

[0023] Preferably, in step S5, the outer diameter tolerance range is 0 to 0.01 mm.

[0024] Preferably, the step S6 specifically includes the following steps:

[0025] S6.1. Prepare assembly parts: prepare composite pole shoes, flat composite pole shoes, connecting rings, half pole shoes and energy transfer heads with the same tolerance band;

[0026] S6.2, Install welding mandrel: Assemble the prepared parts through the tube shell welding mandrel;

[0027] S6.3, Assemble solder wire: Install shaped solder wire at each weld location;

[0028] S6.4. Brazing welding: The assembled components are sent into a hydrogen burning furnace for brazing welding to form a composite tube shell blank.

[0029] Preferably, the step S8 specifically includes the following steps:

[0030] S8.1. Install the magnetic ring: Install the magnetic focusing system that matches the product in the slow-wave circuit section, and install the magnetic ring with a lossless structure cut in a periodic structure;

[0031] S8.2, Fixed magnetic ring: Use a clamp made of dispersed copper material to install the fixed magnetic ring;

[0032] S8.3. Adjust the position of the snap ring: fine-tune the position of the snap ring;

[0033] S8.4. Design and adjust radial height: adjust the radial height of the dispersed copper material on the composite pole shoe to ensure that the outer diameter of the composite pole shoe is basically consistent with the outer diameter of the magnetic ring and the clamping ring. The outer diameter of the composite pole shoe is designed to be 0.05 to 0.1 mm larger than the size of the magnetic ring and the clamping ring after installation and superposition;

[0034] S8.5. Soldering and installing the tube core and the base plate: Ensure that the tube core and the base plate are fully in contact with the fan-shaped surface of the slow-wave circuit section. Apply and fill tin-lead solder on the thermal contact parts and interfaces for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0035] Preferably, in step S1, the pure iron material is DT8A, and the dispersed copper material is TuMAl0.12.

[0036] Preferably, in the step S2, the pole shoe blank rod after nickel plating is cooled by liquid nitrogen to achieve cold shrinkage, and the heated heat sink blank tube is heated by a hot air gun to achieve thermal expansion.

[0037] Preferably, the heat sink portion in the step S1 is designed to be a regular shape, including a regular circle or a fan shape, and the process tooling for the composite tube shell production, processing and tube core centering adopts a conical design.

[0038] Preferably, the brazing welding processes in steps S3 and S6 are both performed using vertical hydrogen furnace gold-nickel-copper solder.

[0039] The present invention provides a method for preparing a high-efficiency and high-power helical traveling wave tube composite tube shell. It has the following beneficial effects:

[0040] 1. The present invention significantly improves production efficiency and product dimensional consistency by upgrading the pole shoe-heat sink combination from the traditional one-by-one brazing method to batch CNC machining manufacturing. It not only improves production efficiency, but also solves the problems of low production efficiency, discrete size and quality in traditional methods.

[0041] 2. The composite pole shoe of the present invention realizes the transition from pure iron to copper material in the raw material stage, which significantly improves the thermal conductivity. The heat sink adopts an annular structure design and a higher-strength dispersed copper material, which avoids the low softening temperature of oxygen-free copper and the risk of deformation of small-sized composite tubes, effectively solves the problems of poor thermal conductivity and low heat dissipation efficiency, and at the same time improves the strength of the heat sink and reduces the risk of deformation.

[0042] 3. The present invention adopts CNC machining to manufacture the pole shoe-heat sink combination, which improves the manufacturing accuracy and consistency of the composite tube shell and simplifies the production and assembly process. By using the heat sink itself as the assembly reference surface, the tooling and mold design are simplified, and the production cost is reduced. The problems of low dimensional accuracy, poor manufacturing consistency, complex tooling, and high production cost in traditional processes are effectively solved, and the process control level of slow-wave circuit alignment and straightness is improved.

[0043] 4. The novel composite tube shell structure and process method of the present invention increases the thermal contact surface through arc or circular contact, shortens the heat conduction path, significantly improves the heat conduction efficiency, and reduces the temperature gradient. The size design of the annular heat sink matches the structure of the magnetic focusing system to form an efficient heat conduction path of composite tube shell-magnetic ring-clamping ring-base plate, which solves the problems of unreasonable design of traditional heat conduction paths, low thermal conductivity, long heat conduction paths, and large temperature gradients.

[0044] 5. The present invention realizes a thermal conductive structure in which the slow-wave circuit and the heat dissipation base plate are in full contact by pouring a thermal conductive medium, which significantly reduces the temperature gradient on the thermal conductive path and improves the thermal conduction efficiency by more than 1 times. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a flow chart of the method of the present invention;

[0046] Figure 2 It is a composite pole shoe blank rod assembly diagram of the present invention;

[0047] Figure 3 It is a composite pole shoe blank rod assembly diagram of the present invention;

[0048] Figure 4 This is a structural diagram of the composite pole piece and composite tube shell of the present invention.

[0049] Among them, 1. Composite pole shoe blank; 1-1. Pole shoe blank rod; 1-2. Heat sink blank tube; 1-3. Gold-copper solder wire; 2. Composite tube shell blank; 2-1. Composite pole shoe; 2-2. Flat composite pole shoe; 2-3. Connecting ring; 2-4. Half pole shoe; 2-5. Energy transmission head; 2-6. Tube shell welding core rod; 3. Slow wave circuit segment; 3-1. Magnetic ring; 3-2. Clamp ring; 3-3. Bottom plate. DETAILED DESCRIPTION

[0050] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0051] Please refer to the attached Figure 1 -Attached Figure 4 The embodiment of the present invention provides a method for preparing a high-efficiency and high-power helical traveling wave tube composite shell, comprising the following steps:

[0052] S1, machining a pole shoe blank rod 1-1 made of pure iron and a heat sink blank tube 1-2 made of dispersed copper;

[0053] S2, using the material thermal expansion clamping technology, the cold-shrink nickel-plated pole shoe blank rod 1-1 is loaded into the heat sink blank tube 1-2 after thermal expansion treatment to form a composite pole shoe blank 1;

[0054] S3, after returning to normal temperature, loading the gold-copper solder wire 1-3 on the heat sink blank tube 1-2 and then performing brazing welding;

[0055] S4, performing nickel plating and sintering treatment on the entire surface of the composite pole piece 2-1;

[0056] S5. Classify the composite pole piece 2-1 according to the outer diameter tolerance band using radial dimension automatic screening equipment;

[0057] S6, assembling the composite pole piece 2-1, the flat composite pole piece 2-2, the connecting ring 2-3, the half pole piece 2-4, and the energy transmission head 2-5 through the tube shell welding mandrel 2-6 and brazing and welding them into a composite tube shell blank 2;

[0058] S7, the composite tube shell blank 2 is loaded into the matching machine processing tooling and fixed, the composite tube shell mandrel is firstly processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method;

[0059] S8. Complete the assembly of the tube core according to the high-frequency circuit assembly process and the tube core welding process.

[0060] In step S1, the pole shoe blank rod 1-1 needs to be subjected to surface nickel plating and sintering treatment.

[0061] The S3 step specifically includes the following steps:

[0062] S3.1, pre-processing a solder groove on the heat sink blank tube 1-2;

[0063] S3.2, loading the gold-copper solder wire 1-3 into the solder groove of the heat sink blank tube 1-2, the solder wire is evenly distributed and fully in contact with the part to be welded;

[0064] S3.3, sending the composite pole shoe blank 1 assembled with solder wire into a hydrogen furnace for brazing welding;

[0065] S3.4. After the brazing is completed, the welded composite pole shoe blank 1 is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked to obtain the composite pole shoe blank 1.

[0066] In step S5, the outer diameter tolerance range is 0 to 0.01 mm.

[0067] Step S6 specifically includes the following steps:

[0068] S6.1. Prepare the assembly parts: prepare the composite pole shoe 2-1, the flat composite pole shoe 2-2, the connecting ring 2-3, the half pole shoe 2-4 and the energy transmission head 2-5 with the same tolerance band;

[0069] S6.2, install welding mandrel: assemble the prepared parts through the tube shell welding mandrel 2-6;

[0070] S6.3, Assemble solder wire: Install shaped solder wire at each weld location;

[0071] S6.4. Brazing welding: The assembled components are sent into a hydrogen burning furnace for brazing welding to form a composite tube shell blank 2.

[0072] Step S8 specifically includes the following steps:

[0073] S8.1. Install the magnetic ring 3-1: Install the magnetic focusing system of the product in the slow-wave circuit section 3, and install the magnetic ring 3-1 with a lossless structure cut in a periodic structure;

[0074] S8.2, fixed magnetic ring 3-1: use a clamp ring 3-2 made of dispersed copper material to install the fixed magnetic ring 3-1;

[0075] S8.3. Adjust the position of the snap ring 3-2: fine-tune the position of the snap ring 3-2;

[0076] S8.4. Design and adjust the radial height: adjust the radial height of the dispersed copper material on the composite pole shoe 2-1 to ensure that the outer diameter of the composite pole shoe 2-1 is basically consistent with the outer diameter of the magnetic ring 3-1 and the clamping ring 3-2. The outer diameter of the composite pole shoe 2-1 is designed to be 0.05 to 0.1 mm larger than the size of the magnetic ring 3-1 and the clamping ring 3-2 after installation and superposition;

[0077] S8.5. Soldering and installing the tube core and the base plate 3-3: Ensure that the tube core and the base plate 3-3 are fully contacted on the fan-shaped surface of the slow-wave circuit segment 3. Apply and fill tin-lead solder on the thermal contact parts and interfaces for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0078] In step S1, the pure iron material is DT8A and the dispersed copper material is TuMAl 0.12.

[0079] In step S2, the nickel-plated pole shoe blank rod 1-1 is cooled by liquid nitrogen to achieve cold shrinkage, and the heated heat sink blank tube 1-2 is heated by a hot air gun to achieve thermal expansion.

[0080] In step S1, the heat sink portion is designed to be a regular shape, including a regular circle or fan-shaped shape, and the process tooling for composite tube shell production, processing and tube core alignment adopts a conical design.

[0081] The brazing welding process in steps S3 and S6 is vertical hydrogen furnace gold-nickel-copper solder.

[0082] Embodiment 1:

[0083] Preparation steps:

[0084] S1: Mechanically process a pole shoe blank rod 1-1 made of pure iron material and a heat sink blank tube 1-2 made of dispersed copper material, wherein the pure iron material is DT8A and the dispersed copper material is TuMAl0.12.

[0085] S2: Using the material thermal expansion clamping technology, the cold-shrinking nickel-plated pole shoe blank rod 1-1 is cooled by liquid nitrogen to achieve cold shrinkage, and is loaded into the heat sink blank tube 1-2 after thermal expansion treatment to form a composite pole shoe blank 1.

[0086] S3: After returning to normal temperature, the gold-copper solder wire 1-3 is loaded on the heat sink blank tube 1-2 and then brazing is performed:

[0087] S3.1: Pre-processing a solder groove on the heat sink blank tube 1-2;

[0088] S3.2: Place gold-copper solder wires 1-3 into the solder tank, with the solder wires evenly distributed and in full contact with the parts to be soldered;

[0089] S3.3: sending the composite pole shoe blank 1 assembled with solder wire into a hydrogen furnace for brazing welding;

[0090] S3.4: After brazing is completed, the welded composite pole shoe blank 1 is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked.

[0091] S4: The composite pole piece 2-1 is subjected to a whole surface nickel plating and sintering treatment.

[0092] S5: Using radial dimension automatic screening equipment, the composite pole shoes 2-1 are classified according to the outer diameter tolerance band of 0 to 0.01 mm.

[0093] S6: Assemble the composite pole piece 2-1, the flat composite pole piece 2-2, the connecting ring 2-3, the half pole piece 2-4, and the energy transfer head 2-5 through the tube shell welding mandrel 2-6 and braze and weld them into a composite tube shell blank 2:

[0094] S6.1: Prepare assembly parts with the same tolerance zone;

[0095] S6.2: Assemble the parts through the tube shell welding mandrel 2-6;

[0096] S6.3: Install shaped solder wire at each weld location;

[0097] S6.4: Send the assembled components into the hydrogen burning furnace for brazing welding.

[0098] S7: The composite tube shell blank 2 is loaded into the matching machine processing tooling and fixed, and the wire hole is processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method.

[0099] S8: Complete the assembly of the tube core according to the high-frequency circuit assembly process and tube core welding process:

[0100] S8.1: Install the magnetic focusing system of the product in the slow wave circuit section 3, and install the magnetic ring 3-1 with a non-destructive structure;

[0101] S8.2: Use the dispersed copper clamp ring 3-2 to fix the magnetic ring 3-1;

[0102] S8.3: Fine-adjust the position of the snap ring 3-2;

[0103] S8.4: Adjust the radial height of the dispersed copper material on the composite pole shoe 2-1 so that the outer diameter of the composite pole shoe 2-1 is basically consistent with the outer diameter of the magnetic ring 3-1 and the clamping ring 3-2. The designed outer diameter is 0.05 to 0.1 mm larger than the size of the magnetic ring and the clamping ring after installation and superposition.

[0104] S8.5: Ensure that the die and base plate 3-3 are fully in contact with the fan-shaped surface installed in the slow-wave circuit section. Apply and fill tin-lead solder at the thermal contact area and interface for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0105] Summarize:

[0106] This embodiment realizes an efficient production process and high-quality composite tube shell manufacturing through basic process steps, ensuring the requirements of high-power heat dissipation and miniaturized design.

[0107] Embodiment 2:

[0108] Preparation steps:

[0109] The following improvements are made on the basis of the first embodiment:

[0110] S1: Mechanically process a pole shoe blank rod 1-1 made of pure iron material and a heat sink blank tube 1-2 made of dispersed copper material, wherein the pure iron material is DT8A and the dispersed copper material is TuMAl0.12.

[0111] The heat sink is designed to be a regular circle, and the process tools for composite tube shell production, processing and tube core alignment adopt a conical design.

[0112] Steps S2 to S8 are the same as those in the first embodiment.

[0113] Summarize:

[0114] On the basis of the first embodiment, the assembly accuracy and heat dissipation performance are further improved by improving the heat sink structure design and process tooling.

[0115] Embodiment three:

[0116] Preparation steps:

[0117] The following improvements are made on the basis of the second embodiment:

[0118] S1: Mechanically process a pole shoe blank rod 1-1 made of pure iron material and a heat sink blank tube 1-2 made of dispersed copper material, wherein the pure iron material is DT8A and the dispersed copper material is TuMAl0.12.

[0119] The heat sink is designed to be a regular circle or fan-shaped, and the process tools for composite tube shell production, processing and tube core centering adopt a conical design.

[0120] S2: Using the material thermal expansion clamping technology, the cold-shrinking nickel-plated pole shoe blank rod 1-1 is cooled by liquid nitrogen to achieve cold shrinkage, and is loaded into the heat sink blank tube 1-2 after thermal expansion treatment to form a composite pole shoe blank 1.

[0121] S3: After returning to normal temperature, the gold-copper solder wire 1-3 is loaded on the heat sink blank tube 1-2 and then brazing is performed:

[0122] S3.1: Pre-processing a solder groove on the heat sink blank tube 1-2;

[0123] S3.2: Place gold-copper solder wires 1-3 into the solder tank, with the solder wires evenly distributed and in full contact with the parts to be soldered;

[0124] S3.3: sending the composite pole shoe blank 1 assembled with solder wire into a hydrogen furnace for brazing welding;

[0125] S3.4: After brazing is completed, the welded composite pole shoe blank 1 is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked.

[0126] S4: The composite pole piece 2-1 is subjected to a whole surface nickel plating and sintering treatment.

[0127] S5: Using radial dimension automatic screening equipment, the composite pole shoes 2-1 are classified according to the outer diameter tolerance band of 0 to 0.01 mm.

[0128] S6: Assemble the composite pole piece 2-1, the flat composite pole piece 2-2, the connecting ring 2-3, the half pole piece 2-4, and the energy transfer head 2-5 through the tube shell welding mandrel 2-6 and braze and weld them into a composite tube shell blank 2:

[0129] S6.1: Prepare assembly parts with the same tolerance zone;

[0130] S6.2: Assemble the parts through the tube shell welding mandrel 2-6;

[0131] S6.3: Install shaped solder wire at each weld location;

[0132] S6.4: Send the assembled components into the hydrogen burning furnace for brazing welding.

[0133] S7: The composite tube shell blank 2 is loaded into the matching machine processing tooling and fixed, and the wire hole is processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method.

[0134] S8: Complete the assembly of the tube core according to the high-frequency circuit assembly process and tube core welding process:

[0135] S8.1: Install the magnetic focusing system of the product in the slow wave circuit section 3, and install the magnetic ring 3-1 with a non-destructive structure;

[0136] S8.2: Use the dispersed copper clamp ring 3-2 to fix the magnetic ring 3-1;

[0137] S8.3: Fine-adjust the position of the snap ring 3-2;

[0138] S8.4: Adjust the radial height of the dispersed copper material on the composite pole shoe 2-1 so that the outer diameter of the composite pole shoe 2-1 is basically consistent with the outer diameter of the magnetic ring 3-1 and the clamping ring 3-2. The designed outer diameter is 0.05 to 0.1 mm larger than the size of the magnetic ring and the clamping ring after installation and superposition.

[0139] S8.5: Ensure that the die and base plate 3-3 are fully in contact with the fan-shaped surface installed in the slow-wave circuit section. Apply and fill tin-lead solder at the thermal contact area and interface for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0140] Summarize:

[0141] On the basis of the second embodiment, the heat dissipation performance and assembly accuracy of the structure are enhanced by further improving the shape design of the heat sink.

[0142] Embodiment 4:

[0143] Preparation steps:

[0144] The following improvements are made based on the third embodiment:

[0145] S1: Mechanically process a pole shoe blank rod 1-1 made of pure iron material and a heat sink blank tube 1-2 made of dispersed copper material, wherein the pure iron material is DT8A and the dispersed copper material is TuMA l 0.12.

[0146] The heat sink is designed to be in a regular shape, including a regular circle or fan-shaped shape, and the process tools for composite tube shell production, processing and tube core centering adopt a conical design.

[0147] S2: Using the material thermal expansion clamping technology, the cold-shrinking nickel-plated pole shoe blank rod 1-1 is cooled by liquid nitrogen to achieve cold shrinkage, and is loaded into the heat sink blank tube 1-2 after thermal expansion treatment to form a composite pole shoe blank 1.

[0148] S3: After returning to normal temperature, the gold-copper solder wire 1-3 is loaded on the heat sink blank tube 1-2 and then brazing is performed:

[0149] S3.1: Pre-processing a solder groove on the heat sink blank tube 1-2;

[0150] S3.2: Place gold-copper solder wires 1-3 into the solder tank, with the solder wires evenly distributed and in full contact with the parts to be soldered;

[0151] S3.3: sending the composite pole shoe blank 1 assembled with solder wire into a hydrogen furnace for brazing welding;

[0152] S3.4: After brazing is completed, the welded composite pole shoe blank 1 is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked.

[0153] S4: The composite pole piece 2-1 is subjected to a whole surface nickel plating and sintering treatment.

[0154] S5: Using radial dimension automatic screening equipment, the composite pole shoes 2-1 are classified according to the outer diameter tolerance band of 0 to 0.01 mm.

[0155] S6: Assemble the composite pole piece 2-1, the flat composite pole piece 2-2, the connecting ring 2-3, the half pole piece 2-4, and the energy transfer head 2-5 through the tube shell welding mandrel 2-6 and braze and weld them into a composite tube shell blank 2:

[0156] S6.1: Prepare assembly parts with the same tolerance zone;

[0157] S6.2: Assemble the parts through the tube shell welding mandrel 2-6;

[0158] S6.3: Install shaped solder wire at each weld location;

[0159] S6.4: Send the assembled components into the hydrogen burning furnace for brazing welding.

[0160] S7: The composite tube shell blank 2 is loaded into the matching machine processing tooling and fixed, and the wire hole is processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method.

[0161] S8: Complete the assembly of the tube core according to the high-frequency circuit assembly process and tube core welding process:

[0162] S8.1: Install the magnetic focusing system of the product in the slow wave circuit section 3, and install the magnetic ring 3-1 with a non-destructive structure;

[0163] S8.2: Use the dispersed copper clamp ring 3-2 to fix the magnetic ring 3-1;

[0164] S8.3: Fine-adjust the position of the snap ring 3-2;

[0165] S8.4: Adjust the radial height of the dispersed copper material on the composite pole shoe 2-1 so that the outer diameter of the composite pole shoe 2-1 is basically consistent with the outer diameter of the magnetic ring 3-1 and the clamping ring 3-2. The designed outer diameter is 0.05 to 0.1 mm larger than the size of the magnetic ring and the clamping ring after installation and superposition.

[0166] S8.5: Ensure that the die and base plate 3-3 are fully in contact with the fan-shaped surface installed in the slow-wave circuit section. Apply and fill tin-lead solder at the thermal contact area and interface for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0167] Summarize:

[0168] On the basis of Example 3, the consistency and performance of the product are further improved by optimizing the nickel plating sintering treatment and size screening process.

[0169] Embodiment five:

[0170] Preparation steps:

[0171] The following improvements are made on the basis of the fourth embodiment:

[0172] S1: Mechanically process a pole shoe blank rod 1-1 made of pure iron material and a heat sink blank tube 1-2 made of dispersed copper material, wherein the pure iron material is DT8A and the dispersed copper material is TuMAl0.12.

[0173] The heat sink is designed to be in a regular shape, including a regular circle or fan-shaped shape, and the process tools for composite tube shell production, processing and tube core centering adopt a conical design.

[0174] S2: Using the material thermal expansion clamping technology, the cold-shrinking nickel-plated pole shoe blank rod 1-1 is cooled by liquid nitrogen to achieve cold shrinkage, and is loaded into the heat sink blank tube 1-2 after thermal expansion treatment to form a composite pole shoe blank 1.

[0175] S3: After returning to normal temperature, the gold-copper solder wire 1-3 is loaded on the heat sink blank tube 1-2 and then brazing is performed:

[0176] S3.1: Pre-processing a solder groove on the heat sink blank tube 1-2;

[0177] S3.2: Place gold-copper solder wires 1-3 into the solder tank, with the solder wires evenly distributed and in full contact with the parts to be soldered;

[0178] S3.3: sending the composite pole shoe blank 1 assembled with solder wire into a hydrogen furnace for brazing welding;

[0179] S3.4: After brazing is completed, the welded composite pole shoe blank 1 is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked.

[0180] S4: The composite pole piece 2-1 is subjected to a whole surface nickel plating and sintering treatment.

[0181] S5: Using radial dimension automatic screening equipment, the composite pole shoes 2-1 are classified according to the outer diameter tolerance band of 0 to 0.01 mm.

[0182] S6: Assemble the composite pole piece 2-1, the flat composite pole piece 2-2, the connecting ring 2-3, the half pole piece 2-4, and the energy transfer head 2-5 through the tube shell welding mandrel 2-6 and braze and weld them into a composite tube shell blank 2:

[0183] S6.1: Prepare assembly parts with the same tolerance zone;

[0184] S6.2: Assemble the parts through the tube shell welding mandrel 2-6;

[0185] S6.3: Install shaped solder wire at each weld location;

[0186] S6.4: Send the assembled components into the hydrogen burning furnace for brazing welding.

[0187] S7: The composite tube shell blank 2 is loaded into the matching machine processing tooling and fixed, and the wire hole is processed by the electric spark punching machine, and then the input / output tube shell is processed by the slow wire processing method.

[0188] S8: Complete the assembly of the tube core according to the high-frequency circuit assembly process and tube core welding process:

[0189] S8.1: Install the magnetic focusing system of the product in the slow wave circuit section 3, and install the magnetic ring 3-1 with a non-destructive structure;

[0190] S8.2: Use the dispersed copper clamp ring 3-2 to fix the magnetic ring 3-1;

[0191] S8.3: Fine-adjust the position of the snap ring 3-2;

[0192] S8.4: Adjust the radial height of the dispersed copper material on the composite pole shoe 2-1 so that the outer diameter of the composite pole shoe 2-1 is basically consistent with the outer diameter of the magnetic ring 3-1 and the clamping ring 3-2. The designed outer diameter is 0.05 to 0.1 mm larger than the size of the magnetic ring and the clamping ring after installation and superposition.

[0193] S8.5: Ensure that the die and base plate 3-3 are fully in contact with the fan-shaped surface installed in the slow-wave circuit section. Apply and fill tin-lead solder at the thermal contact area and interface for welding. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

[0194] Summarize:

[0195] On the basis of Example 4, the consistency and performance of the product are further improved by optimizing the nickel plating sintering treatment and size screening process.

[0196] Summary:

[0197] By gradually optimizing material selection, structural design, and process flow, the five embodiments gradually upgraded from basic efficient production and high-quality manufacturing to heat sink structure optimization, brazing process improvement, and assembly precision improvement, ultimately achieving extremely high production efficiency and product performance. These improvements not only solved key problems in traditional processes, but also provided comprehensive technical support for the manufacture of high-power, millimeter-wave helical traveling wave tubes.

[0198] Experiment 1: Thermal path temperature gradient and thermal conduction efficiency experiment

[0199] Purpose: To verify whether the present invention can significantly reduce the temperature gradient on the heat conduction path and improve the heat conduction efficiency.

[0200] method:

[0201] Sample preparation: 6 samples were prepared using the traditional method and the technical solution of the present invention.

[0202] Temperature gradient measurement: Use thermocouples to measure the temperature at different locations along the heat conduction path and calculate the temperature gradient.

[0203] Thermal conductivity measurement: The thermal conductivity of the sample was measured by a heat flow meter.

[0204] step:

[0205] Fix the two groups of samples on the same heat source and keep the temperature of the heat source constant.

[0206] The temperature was recorded using multiple thermocouples at different locations on the sample (heat sink, pole piece, base plate).

[0207] Calculate the temperature gradient along the heat conduction path.

[0208] The heat transfer efficiency was measured using a heat flow meter.

[0209] Compare the temperature gradient and heat conduction efficiency of the two groups of samples.

[0210] Table 1:

[0211]

[0212]

[0213] Summary: Through the comparison of experimental data, it can be seen that the temperature gradient of the samples produced by the traditional method is maintained at 30℃ / cm, while the temperature gradient of the samples produced by the present invention is reduced to 20℃ / cm. At the same time, the average thermal conductivity efficiency of the samples produced by the traditional method is 202.67W / m·K, while the average thermal conductivity efficiency of the samples produced by the present invention is 407.5W / m·K, which is more than doubled. This shows that the present invention has significant advantages in significantly reducing the temperature gradient on the heat conduction path and improving the heat conduction efficiency.

[0214] Experiment 2: Production efficiency and size consistency experiment

[0215] Purpose: To verify whether the present invention can significantly improve production efficiency and product dimensional consistency.

[0216] method:

[0217] Sample production: Six samples were produced using the conventional one-by-one brazing method and the batch CNC machining method of the present invention.

[0218] Production efficiency measurement: Production time of both methods was recorded.

[0219] Dimensional consistency measurement: Use high-precision measuring instruments to measure the key dimensions of each sample and calculate dimensional deviations.

[0220] step:

[0221] Six samples were produced using both methods.

[0222] The total production time for each method was recorded.

[0223] Use high-precision measuring instruments to measure the key dimensions of each sample, such as heat sink thickness, pole shoe diameter, etc.

[0224] Production efficiency and dimensional consistency were calculated for each method.

[0225] Table 2:

[0226]

[0227]

[0228] Summary: The experimental results show that the traditional method takes an average of about 10 hours to produce 6 samples, with a production efficiency of 0.6 samples / hour and a dimensional deviation of ±0.1mm. The method of the present invention takes an average of about 6 hours to produce 6 samples, with a production efficiency of 1 sample / hour and a dimensional deviation of ±0.05mm. This shows that the present invention significantly improves production efficiency, and the dimensional consistency and accuracy are significantly better than the traditional method.

[0229] Experiment 3: Thermal conductivity and heat dissipation efficiency experiment

[0230] Purpose: To verify whether the present invention can significantly improve thermal conductivity and heat dissipation efficiency and reduce deformation risk.

[0231] method:

[0232] Sample preparation: 6 samples of traditional pure iron material and 6 samples of the transition from pure iron to copper material in the present invention were prepared.

[0233] Thermal conductivity measurement: The thermal diffusivity of the samples was measured using the laser flash method.

[0234] Heat dissipation efficiency measurement: Under constant power, an infrared thermal imager is used to measure the temperature distribution on the sample surface.

[0235] Deformation risk assessment: Perform thermal cycle tests on samples to measure dimensional changes before and after thermal cycles.

[0236] step:

[0237] Six samples of each material were prepared.

[0238] The thermal diffusivity of the samples was measured using the laser flash method.

[0239] The sample was operated at a constant power, and the surface temperature distribution was recorded using an infrared thermal imager to calculate the heat dissipation efficiency.

[0240] The sample is subjected to multiple thermal cycle tests (eg, 200 times) and the dimensional changes before and after the thermal cycles are measured.

[0241] Table 3:

[0242]

[0243]

[0244] Summary: Experimental data show that the average thermal diffusivity of samples using the traditional method is 20.33 mm 2 / s, the maximum surface temperature is 99.33°C, and the average dimensional change after thermal cycling is -0.11mm; while the average thermal diffusivity of the sample of the present invention is 41.17mm 2 / s, the maximum surface temperature is 79.17°C, and the dimensional change after thermal cycling is 0mm. This shows that the present invention significantly improves thermal conductivity and heat dissipation efficiency while effectively reducing the risk of deformation.

[0245] Experiment 4: Manufacturing accuracy and consistency experiment

[0246] Purpose: To verify whether the present invention can improve manufacturing accuracy and consistency, simplify the production and assembly process, and reduce production costs.

[0247] method:

[0248] Sample production: Six pole shoe-heat sink combination samples were produced using the conventional method and the method of the present invention respectively.

[0249] Manufacturing accuracy measurement: Use a coordinate measuring machine to measure the key dimensions of each sample and calculate dimensional deviations.

[0250] Production cost analysis: Record the production costs of both methods, including materials, labor hours, tooling, etc.

[0251] step:

[0252] Six samples were produced using both methods.

[0253] Use a three-dimensional coordinate measuring machine to measure the key dimensions of each sample, such as heat sink thickness, pole shoe diameter, etc.

[0254] The dimensional deviation and agreement were calculated for each method.

[0255] Record the production cost of each method and conduct a comparative analysis.

[0256] Table 4:

[0257]

[0258]

[0259] Summary: The experimental results show that the dimensional deviation of the samples produced by the traditional method is ±0.1mm, and the production cost is 50 yuan / sample; while the dimensional deviation of the samples produced by the method of the present invention is ±0.05mm, and the production cost is 30 yuan / sample. This shows that the present invention significantly reduces the production cost and simplifies the production and assembly process while improving the manufacturing accuracy and consistency.

[0260] Experiment 5: Thermal contact surface and thermal conduction path experiment

[0261] Purpose: To verify that the present invention increases the thermal contact surface through arc or circular contact, shortens the heat conduction path, improves the heat conduction efficiency, and reduces the temperature gradient.

[0262] method:

[0263] Sample preparation: 6 composite tube shell samples of the conventional structure and the arc-shaped or circular contact structure of the present invention were prepared respectively.

[0264] Thermal contact surface measurement: Use a 3D scanner to measure the thermal contact surface area of ​​the sample.

[0265] Heat Transfer Path Measurement: Use thermocouples and heat flow meters to measure the heat transfer path and efficiency of the sample.

[0266] Temperature gradient measurement: Use thermocouples to measure the temperature at different locations along the heat conduction path and calculate the temperature gradient.

[0267] step:

[0268] Two types of samples were prepared, 6 samples of each structure.

[0269] The thermal contact surface area was measured using a 3D scanner.

[0270] Use thermocouples and heat flow meters to measure heat transfer paths and efficiencies.

[0271] Record the temperature at different locations along the heat conduction path and calculate the temperature gradient.

[0272] Table 5:

[0273]

[0274] Summary: Experimental data show that the average thermal contact area of ​​samples using the traditional method is 20.67 cm 2, the heat conduction path is 5 cm, the heat conduction efficiency is 205 W / m·K, and the temperature gradient is 29.67°C / cm; while the average thermal contact surface area of ​​the sample of the present invention is 41.17 cm 2 , the heat conduction path is 3cm, the heat conduction efficiency is 407.5W / m·K, and the temperature gradient is 19.67℃ / cm. This shows that the present invention increases the thermal contact surface and shortens the heat conduction path through the arc or circular contact structure, significantly improves the heat conduction efficiency, and reduces the temperature gradient.

[0275] Summary:

[0276] Based on the above experimental results, the technical solution of the present invention is significantly superior to the traditional method in many aspects. Specifically, the present invention can significantly reduce the temperature gradient on the heat conduction path and improve the heat conduction efficiency by more than 1 times; the pole shoe-heat sink combination is manufactured by CNC machining, which improves the production efficiency and the dimensional consistency of the product; through material transition and structural design optimization, the thermal conductivity and heat dissipation efficiency are significantly improved, and the risk of deformation is reduced; the use of advanced processing and assembly methods improves the manufacturing accuracy, the tube core centering process control ability and consistency, and reduces the production cost. The superiority of the present invention in terms of thermal conductivity, production efficiency, manufacturing accuracy, etc. has been verified, and its significant value in practical applications has been further demonstrated.

[0277] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a high-efficiency, high-power helical traveling wave tube composite shell, characterized in that: The following steps are involved: S1, machining a pole shoe blank rod (1-1) made of pure iron material and a heat sink blank tube (1-2) made of dispersed copper material; S2, using a material thermal expansion clamping technology, placing the cold-shrink nickel-plated pole shoe blank rod (1-1) into the heat sink blank tube (1-2) after thermal expansion treatment, to form a composite pole shoe blank (1); S3, after returning to normal temperature, inserting gold-copper solder wire (1-3) into the heat sink blank tube (1-2) and then performing brazing welding; S4, performing a nickel plating and sintering treatment on the entire surface of the composite pole piece (2-1); S5. Classifying the composite pole shoes (2-1) according to the outer diameter tolerance band using radial dimension automatic screening equipment; S6, assembling the composite pole shoe (2-1), the flat composite pole shoe (2-2), the connecting ring (2-3), the half pole shoe (2-4), and the energy transmission head (2-5) through the tube shell welding mandrel (2-6) and brazing and welding them into a composite tube shell blank (2); S7, the composite tube shell blank (2) is loaded into a matching machining tool and fixed, and the composite tube shell core rod is firstly processed by an electric spark punching machine, and then the input / output tube shell is processed by a slow wire cutting method; S8. Complete the assembly of the tube core according to the high-frequency circuit assembly process and the tube core welding process.

2. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: In the step S1, the pole shoe blank rod (1-1) needs to be subjected to surface nickel plating and sintering treatment.

3. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: The S3 step specifically includes the following steps: S3.

1. Pre-processing a solder groove on the heat sink blank tube (1-2); S3.2, loading the gold-copper solder wire (1-3) into the solder groove of the heat sink blank tube (1-2), the solder wire is evenly distributed and fully in contact with the part to be welded; S3.3, sending the composite pole shoe blank (1) assembled with solder wire into a hydrogen furnace for brazing welding; S3.

4. After the brazing is completed, the welded composite pole shoe blank (1) is taken out from the hydrogen furnace, cooled to room temperature, and the welding quality is checked to obtain the composite pole shoe blank (1).

4. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: In the step S5, the outer diameter tolerance range is 0 to 0.01 mm.

5. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: The step S6 specifically includes the following steps: S6.

1. Prepare assembly parts: prepare composite pole shoes (2-1), flat composite pole shoes (2-2), connecting rings (2-3), half pole shoes (2-4) and energy transfer heads (2-5) with the same tolerance band; S6.2, install welding mandrel: assemble the prepared parts through the tube shell welding mandrel (2-6); S6.3, Assemble solder wire: Install shaped solder wire at each weld location; S6.

4. Brazing welding: The assembled components are sent into a hydrogen burning furnace for brazing welding to form a composite tube shell blank (2).

6. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: The step S8 specifically includes the following steps: S8.

1. Install the magnetic ring (3-1): Install the magnetic focusing system of the product in the slow wave circuit section (3), and install the magnetic ring (3-1) with a lossless structure cut in a periodic structure; S8.2, fixed magnetic ring (3-1): use a clamping ring (3-2) made of dispersed copper material to install the fixed magnetic ring (3-1); S8.

3. Adjust the position of the snap ring (3-2): fine-tune the position of the snap ring (3-2); S8.

4. Design and adjust the radial height: adjust the radial height of the dispersed copper material on the composite pole shoe (2-1) to ensure that the outer diameter of the composite pole shoe (2-1) is basically consistent with the outer diameter of the magnetic ring (3-1) and the retaining ring (3-2). The outer diameter of the composite pole shoe (2-1) is designed to be 0.05 to 0.1 mm larger than the size of the magnetic ring (3-1) and the retaining ring (3-2) after installation and superposition; S8.

5. Soldering and installing the tube core and the base plate (3-3): Ensure that the tube core and the base plate (3-3) are fully in contact with each other on the fan-shaped surface of the slow-wave circuit section (3). Apply and fill tin-lead solder at the thermal contact parts and interfaces for soldering. After debugging and confirming the electrical performance, use thermal conductive glue to fix and fill.

7. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: In the step S1, the pure iron material is DT8A, and the dispersed copper material is TuMAl0.

12.

8. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: In the step S2, the nickel-plated pole shoe blank rod (1-1) is cooled by liquid nitrogen to achieve cold shrinkage, and the heated heat sink blank tube (1-2) is heated by a hot air gun to achieve thermal expansion.

9. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: In the step S1, the heat sink portion is designed to be a regular shape, including a regular circle or a fan shape, and the process tooling for the composite tube shell production, processing and tube core alignment adopts a conical design.

10. The method for preparing a high-efficiency and high-power helical traveling wave tube composite shell according to claim 1, characterized in that: The brazing welding processes in steps S3 and S6 are both performed using vertical hydrogen furnace gold-nickel-copper solder.

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