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卫星姿态控制飞轮壳体是宇航飞行器中一种典型的密封薄壳结构,是飞轮机构的主要结构组成之一。它既要确保长寿命飞轮在三轴稳定卫星上的可靠工作环境,又是装配飞轮总体和连接星体的主要构件。按现代空间薄壁结构力学理论设计的薄壳结构,是一种最可行的设计方案,在工程上为一拉伸焊接结构。由于飞轮机构诸元部件性能的要求和结构上的限制,壳体经施焊成形后,不再允许按常规工艺进行热处理以消除残余应力或校形,并且焊缝质量的检验需用非破坏方法进行。故选用何种焊接工艺和检验方法是予研飞轮壳体中一个重要的技术难点。本文首先对电子束焊接技术的发展与应用作了扼要介绍,随后以一种密封式予研飞轮壳体为典型工件,详述了应用电子束焊接工艺与x射线等检验手段的研制方法和结果。检验中,测得其焊接跟踪、焊缝形状、气孔分布、熔透性、显微组织、残余应力等,均达到较满意结果。从而证实了飞轮壳体构件应用电子束焊接工艺和所用的检验方法是可行的。
Satellite Attitude Control Flywheel housing is a typical sealed shell structure in spacecraft and is one of the main structural components of flywheel mechanism. It not only ensures the reliable working environment of the long-life flywheel on the three-axis stable satellite, but also is the main component of the flywheel assembly and the connecting astral. The thin shell structure, which is designed according to the theory of modern thin-walled structures in space, is one of the most feasible designs and is a tensile welded structure in engineering. Due to the performance requirements and structural limitations of various components of the flywheel mechanism, the shell is no longer allowed to be heat-treated by conventional processes to eliminate residual stress or shape after the welding process, and the quality of the weld is inspected with a non-destructive method get on. So choose what kind of welding process and test method is to study the flywheel housing an important technical difficulties. In this paper, the development and application of electron beam welding technology are briefly introduced. Then a kind of sealed prefabricated flywheel housing is taken as a typical workpiece. The methods and results of the application of electron beam welding technology and x-ray inspection methods are described in detail. During the test, the welding tracking, the shape of weld, the distribution of stomata, the permeability, the microstructure and the residual stress were measured and the results were satisfactory. It is proved that it is feasible to apply the electron beam welding process and the inspection method to the flywheel housing components.