Shape-Performance Testing and Engineering Application of Antenna Components Formed by Selected Laser Melting Components for Space Service Environment

Fig. 1. Prediction of part surface deviation. (a) Top view of antenna body; (b) bottom view of antenna body; (c) antenna bracket; (d) installation plate

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Fig. 2. Stress and failure prediction of parts. (a) Stress analysis of antenna body; (b) failure analysis of antenna body; (c) stress analysis of antenna bracket; (d) failure analysis of antenna bracket; (e) stress analysis of installation plate; (f) failure analysis of installation board

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Fig. 3. Deviation prediction of anti-deformation parts. (a) Top view of antenna body; (b) bottom view of antenna body; (c) antenna bracket; (d) installation board

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Fig. 4. Stress and failure prediction of anti-deformation parts. (a) Stress analysis of antenna body; (b) failure analysis of antenna body; (c) stress analysis of antenna bracket; (d) failure analysis of antenna bracket; (e) stress analysis of installation plate; (f) failure analysis of installation board

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Fig. 5. Impact response spectrum test. (a) X-direction; (b) Y-direction; (c) Z-direction

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Fig. 6. Sine/random vibration test. (a) X-direction; (b) Y-direction; (c) Z-direction

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Fig. 7. Thermal vacuum test

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Fig. 8. Part contour defects before and after contour scanning. (a) Before contour scanning; (b)after contour scanning

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Table 1. Process parameters
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Table 1. Process parameters
Parameter Contour velocity /（mm/s） Filling speed /（mm/s） Supporting speed /（mm/s） Contour power /W Filling power /W Supporting power /W
Value 500 1600 1400 340 420 350

Table 2. Scanning strategy
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Table 2. Scanning strategy
Parameter Fill spacing S /mm Rotation angle $θ$ /（°） Area width /mm Area size /mm Minimum bandwidth /mm
Value 0.16 67 10 6 10

Table 3. Element contents of AlSi10Mg alloy powder
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Table 3. Element contents of AlSi10Mg alloy powder
Element Al Si Mg Cu Mn Ni Fe Ti C
Mass fraction /% 6.4000 100.0000 30.0000 340.0000 420.0000 ≤0.0500 ≤0.5500 ≤0.1500 ≤0.0075

Table 4. Deviations of part key feature sizes

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Table 4. Deviations of part key feature sizes

Part	Position	Designed value /mm	Actual value /mm	Deviation /mm
Antenna body	Outer edge outer diameter	82.5	82.75	0.25
Antenna body	Base distance	32.0	32.05	0.05
Antenna bracket	Height	136.0	136.20	0.20
	Inner diameter of upper mounting surface	73.6	73.20	0.40
	Outer diameter of upper mounting surface	90.0	90.10	0.10
	Outer diameter of lower mounting surface	104.0	104.08	0.08
Installation board	Inner diameter of upper mounting surface	85.0	84.55	0.45
	Outer contour of upper mounting surface 1	90.0	90.25	0.25
	Outer contour of upper mounting surface 2	200.0	200.18	0.18
	Distance from upper surface to inside of mounting plate	36.0	35.94	0.06

Table 5. Deviations of pore-like key feature sizes
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Table 5. Deviations of pore-like key feature sizes
Parameter Hole 1 Hole 2 Hole 3 Hole 4 Hole 5 Hole 6
Designed size /mm 2.05 2.80 2.80±0.10 3.00 4.50 4.60
Actual size /mm 2.37 2.64 2.60 2.78 4.48 4.24
Deviation /mm 0.32 0.16 0.10 0.22 0.02 0.36

Table 6. Deviation of thin-walled key feature sizes
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Table 6. Deviation of thin-walled key feature sizes
Parameter Thin wall 1 Thin wall 2 Thin wall 3 Thin wall 4
Designed size /mm 1.41 1.39 2.00 2.00
Actual size /mm 1.59 1.50 2.00 2.00
Deviation /mm 0.019 0.110 0 0

Table 7. Sample hardness test data
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Table 7. Sample hardness test data
Sample state Detected value /HV Average value /HV
First Second Third
Sedimentary state 123 124 123 123
Heat treated state 116 113 115 115

Table 8. Sample tensile test data

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Table 8. Sample tensile test data

Sample state	Average tensile strength R_m /MPa	Average plastic elongation strength $R_{P 0.2}$ /MPa	Average elongation after fracture /%	Average area reduction /%
Sedimentary state	499	258	6.8	10.7
Heat treated state	256	173	16.5	41.3

Table 9. Analysis of part compensation effect

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Table 9. Analysis of part compensation effect

Part	Maximum deformation deviation /mm			Maximum equivalent stress /MPa		Forming risk
Part	Before optimization		After optimization	Before optimization	After optimization	Before optimization	After optimization
Antenna body	0.25	0.03		368.37	364.35	Local high risk	Local medium risk
Antenna bracket	0.38	0.23		368.39	364.41	Local medium risk	Local medium risk
Installation board	0.85	0.10		259.69	251.44	No risk	No risk

Table 10. Error analysis of deformation values between anti-deformation and actual parts
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Table 10. Error analysis of deformation values between anti-deformation and actual parts
Part Maximum simulated deformation /mm Maximum actual deformation /mm Error /%
Antenna body 0.03 0.05 40.0
Antenna bracket 0.23 0.40 42.5
Installation board 0.10 0.18 44.4

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Tianyu Chen, Jie Bao, Yong Kong. Shape-Performance Testing and Engineering Application of Antenna Components Formed by Selected Laser Melting Components for Space Service Environment[J]. Chinese Journal of Lasers, 2024, 51(24): 2402304

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