复杂曲面频率选择表面雷达罩的投影法激光刻蚀加工新技术基础研究

The aircraft's stealth technology is currently one of the competition focuses and commanding heights in the aviation and military field among the world powers. The frequency selective surface (FSS) technology, which can effectively reduce the radar cross-section of radome, has played an important role to improve the stealth performance of the air carrier target. However, due to the huge gap with the United States, Russia and other air powers in the ultra-precision CNC machine tools and the advanced manufacturing technology, how to fabricate freeform surface FSS radome with high-efficiency and high-precision has become a bottleneck restricting the development of major projects in the related engineering areas in china. In this proposal, we use a novel projective galvanometer scanning laser etching (PGSLA) technology as the solution for fabrication of the freeform surface FSS radome. The processing principle, algorithms, technological rules and the internal mechanism during the whole processing cycle are going to be thoroughly studied, using the methods of modeling and simulation, optimization design, testing and analysis, etc. The irregular division-projection-merging algorithm of large scale freeform surface FSS cell patterns and the error compensation mechanism will be designed and optimized; the evaluation and diagnosis method of focused laser beam quality under the projection condition on freeform surface will be explored; and the etching mechanisms between laser irradiation and metal/composite multilayer material system such as the microscopic force-heat-light coupling theory are hoped to be revealed. The project is expected to provide fundamental theory and enabling manufacturing technology support for China's independent research and development of high performence stealth radome.

飞行器的隐身技术是当前世界各大国在航空、军事领域科技竞争的焦点和制高点之一。采用频率选择表面（FSS）技术制造的雷达天线罩，能够有效地缩减雷达反射截面，是改善载体目标隐身性能的重要手段。由于与美、俄等航空强国在超精密数控机床和极限制造技术水平上的巨大差距，如何高效率、高精度地加工制造出复杂曲面FSS雷达罩已成为制约我国相关领域重大工程研制的瓶颈难题。本项目以复杂曲面FSS雷达罩为研究对象，提出投影法振镜扫描激光刻蚀的新加工制造技术，以加工过程各环节的工序算法、工艺规律、内在机理为主线，利用建模仿真、优化设计、试验分析等方法，系统研究复杂曲面FSS单元周期图形的非规则分区拼接优化算法与误差补偿机制，探索曲面投影条件下的聚焦激光光束质量评价与诊断方法，揭示激光刻蚀金属/复合材料多层组合材料体系的界面效应与微观力-热-光的耦合作用，为提高我国飞行器隐身雷达罩的自主研制水平提供理论和使能技术支撑。

通过外形设计、吸波涂料及高阻抗表面等方法，现代先进战机的机体雷达反射截面(RCS)已经非常小，唯其自身雷达系统是一个强散射源，促使频率选择表面(FSS)雷达天线罩的设计与加工制造成为当前世界各大国在航空、军事领域科技竞争的焦点和制高点之一。本项目以复杂曲面 FSS 雷达罩为研究对象，提出平行投影振镜扫描（PPGS）激光精密刻蚀的新加工原理，以加工过程各环节的工序算法、工艺规律、内在机理为主线，利用建模仿真、优化设计、试验分析等方法，系统研究了复杂曲面FSS单元周期图形的非规则分区拼接优化算法与误差补偿机制，创新设计了多种激光束时空特性调控方法、工件标定算法、专用夹具和量具，自主研发了多光束并行超快激光投影式精密刻蚀成套装备及专用工艺软件，系统试验加工了多种类型曲面雷达罩FSS样品，测试了其传输特性曲线，验证了PPGS激光精密加工技术可以兼容平面、规则曲面及复杂曲面雷达罩FSS的加工制造，是解决大型复杂曲面雷达罩FSS的高效率、“跨尺度”加工制造的可行技术方案，为提高我国飞行器隐身雷达罩的自主研制水平提供一项使能技术支持。项目还面向海工装备、微电子、电力能源、管道、模具制造等工业领域，开展了复杂金属零部件超高粘附力超疏水表面、抗生物附着腐蚀、图形化纳米颗粒可控沉积、管道内壁面微结构、超硬材料表面闭环精细抛光等系列应用研究，掌握了丰富的工程应用经验，初步实现了从基础研究向工程应用的转化。项目研究成果在Optics Letters、Applied Surface Science等期刊或会议上共发表学术论文19篇，申请发明专利20项（已授权14项），获得软件著作权2项，培养青年博士讲师2人、博士后1人、硕士研究生7人，产业化成果获得了中国发明协会第九届国际发明展览会“发明创业奖·项目奖”金奖、中国机械工业联合会科技进步二等奖、温州市科学技术奖技术发明一等奖等多项省部级、市级科技奖励。