What would your guess be on the relative cost differences for Chinese industry specifically for a modest frigate sized radar, between AESA, PESA, and mechanical? What are your thoughts on cost effectiveness?
My thoughts.
Volume in manufacturing the elements. The more elements you make the lower the unit costs go down. And they can keep going down and down.
S-band elements. You're making plenty of these for the Type 346 family radars on the 052C/D, 055 and even the carriers. Like previously mentioned, you can save on the element faces by rotating them, either in a single or dual faced layout similar to SAMPSON. You probably have seen the "Chinese Lantern" radome used in some of the Type 054B fan CG, and this is based on an actual prototype or mockup in Wuhan. The "Lantern" has been depicted also on rough drawings by "big fish" leaks.
There is the second option of using a fixed four faced design that is smaller, lets say, for one face, half of the elements of the Type 346A or B.
C-band elements. You need a C-band AESA to replace the Type 364 mechanical radar that serves as a surface search radar for sea skimming missiles, aircraft and ships. The Type 364 has been a must radar feature of every PLAN ship since the Type 052B and the Type 054. You should be making a lot of these for the allegedly AESA radars on HQ-9 ground units, and as elements for the missile target illuminators on the Type 346 family of radars. You also need these elements if you plan on using a target illuminator for HQ-9 missiles, speculatively assuming the new frigate would use these missiles.
X-band elements. You will need one or two X-band AESA to replace the Type 344 gun FCR, the Type 366 FCR for antiship missiles, the navigation radars, and the Front Dome illuminators for the HQ-16. This one gets easier since you are already making these for fighter radars.
The collateral cost advantage of making them for the new frigates would be to lower the costs of these for the primary users as well. The more you make, the better for all.
It also helps when you have this strategic background advantage. Gallium being the most important element for AESAs.
Yttrium is an important element for use in phase shifters for both AESAs and PESAs. China corners its production with over 90%.
Mechanical radars are subject to mechanical stress, wear and tear. There is going to be some lifetime cost for their repair and maintenance. When something happens on sea, they are much harder to repair if that is even possible. With fixed faced AESAs on an integrated mast, all you have to do is run diagnostics to check for every element, locate the burned out ones, and replace the elements internally from the back, pull the bad ones out, and slip the spare ones in. The ship just needs to carry a stock of spare elements. That's a huge qualitative advantage of AESA you can't put a price on.
But of course, there is the issue if you are using a two faced AESA that is set on a mechanical rotation like SAMPSON. This design is still subject to mechanical wear and tear and it isn't as accessible for repair as a fixed four faced one inside an integrated mast. That's going to be the problem if China adopts the "Lantern" radar for the 054B. There is also an alternative mast design that was shown in 2016 for a proposed frigate export to Pakistan that I like better. It has four fixed faces.
Close up of the mast.
If China is willing to offer this back in 2016 as an export item for a poor country like Pakistan, I would assume the costs are not so high.
IMO, China should not rush the Type 054A successor, and it needs to think and rethink the radar configurations and options for this ship carefully, or you are going to be saddled with the next three to four decades and 20 to 30 ships with those decisions. It might be my wishful thinking that the delays for this ship comes from internal debate about the radar sets and configurations, not to mention the choices and development of new MRSAMs for the ship, and which there is also going to be a tie in between the new radars and the SAMs, the latter will then affect your choice of VLS, and this in turn leads to a chain reaction of choices that reverberate through out the ship.