Previously we established that the combination of new machining parameters for openbacked
monolithic lightweighted ZERODUR® mirror substrates, coupled with new methods for optical
finishing of aggressively lightweighted mirrors, have relieved classical mirror design constraints imposed
upon 1.2m diameter lightweight mirrors. We demonstrate that openback mirror substrates now offer
comparable mass, Eigenfrequency and substructure print-through performance to the sandwich-mirror
architecture, but with considerably less manufacturing effort than for sandwich mirrors. Here we extend
the analyses of the first paper from 1.2m diameter down to 0.6m in diameter and up to 2.4m diameter and
4m diameter mirrors.
Recent game-changing technology greatly extends the design possibilities and range of applications for aggressively lightweighted open-back Zerodur® mirrors. We have compared several lightweighting design approaches under this new technology. Analytic comparisons are for 1.2m mirrors, all constrained to have a free-free first Eigenfrequency of 200 Hz. Figures of merit include resulting mass, thickness and relative cost. Much more aggressive masses are now available in open-back mirrors, competitive with the more expensive closed-back sandwich mirrors. These breakthroughs are relevant to spaceborne implementation of lightweight mirrors ranging from a few tenths of a meter in diameter to up to 4 meters in diameter.
Modern day telescopes for astronomy have very complex requirements. Both ground and space based telescopes
are getting much larger placing significant productivity requirements on the manufacturing processes employed.
Conventional manufacturing paradigms involving mechanical abrasion have limitations related primarily to the
material removal mechanisms employed. Reactive Atom Plasma (RAPTM) processing is a sub-aperture, non-contact,
deterministic figuring technology performed at atmospheric pressures. The process has high material
removal rates, and given the non-contact and atmospheric nature lends itself very well to scaling up for large
aperture mirrors/segments. The process also benefits from its ability to simultaneously remove sub-surface
damage (SSD) while imparting the desired figure to the surface. Developments are under way currently to scale
the process up towards larger clear apertures while being able to figure in high spatial frequency features.
Direct Sintered Silicon Carbide (SSiC) is a promising material to fabricate large (over 1 meter diameter) land and space
based mirror optics due to its low areal density, high stiffness and high thermal stability. To make large mirror optics for
visible wavelength applications, sub-nanometer surface roughness is required, which can be achieved by cladding a SSiC
substrate using SiC chemical vapor deposition (CVD). Limitations on available equipment to clad monolithic structures
of this size require that smaller segments need to be clad first and then joined prior to being optically finished. To
demonstrate the viability of this method of fabrication, a segmented &nullset;300mm visible quality lightweighted concave
mirror has been manufactured and characterized. The mirror's 6 radial segments, coated with a SiC CVD layer on the
SSiC substrate were joined by means of a silicon based braze, formulated so that its thermal expansion matched that of
the SSiC substrate and SiC CVD layer. After figuring and polishing to optical quality, the mirror's stability was
characterized under vacuum at three temperatures (120 K, 293 K, and 520 K) by measuring the wave front error (WFE).
Polishing has traditionally been a process of mechanical abrasion with each iteration removing the damage from the
previous iteration. Modern sub-aperture techniques such as CCOS, MRF polishing etc. have added a considerable
amount of determinism to this iterative approach. However, such approaches suffer from one significant flaw, i.e., the
algorithms are completely guided by figure error. This approach fails when there is a considerable amount of strain
energy stored in the substrate and becomes very evident when the aspect ratio of the mirror increases significantly
causing relaxation of strain energy to have deleterious and unpredictable effects on figure between iterations. This is
particularly pronounced when the substrate is made of a hard ceramic such as silicon carbide requiring a considerable
amount of pressure to obtain any appreciable material removal rate. This paper presents an alternate approach involving
a stress-free figuring step and a buffing step intended to recover the surface roughness.
Yogesh Verma, Andrew Chang, John Berrett, Kenneth Futtere, George Gardopee, Jude Kelley, Thomas Kyler, Jeonghwa Lee, Nick Lyford, David Proscia, Phillip Sommer
Mechanical grinding and shaping of optical materials imparts damage that manifests itself as defects and cracks that can propagate well below the surface of the optic. Mitigation of damage is necessary to preserve the integrity of the optic and relieve residual stress that can be detrimental to its performance. Typically, a sequence of subsequent polishing steps with finer and finer grit sizes is used to remove damage, but the process can be painfully slow especially for hard materials such as silicon carbide and often fails to remove all the damage. Reactive Atom Plasma (RAPTM) processing, a non-contact, atmospheric pressure plasma-based process, has been shown to reveal and mitigate sub-surface damage in optical materials. Twyman stress tests on thin glass and SiC substrates demonstrate RAP's ability to relieve the stress while at the same time improving surface form.
A program to fabricate a large, optically fast, aspheric lightweight Be mirror was initiated in order to demonstrate state-of-the-art technology. The mirror blank was fabricated as a 1.0 m diameter, f/0.58 ellipse directly from IP-70 grade powder using near-net-shape hot isostatic pressing (HIPing) and a patented tooling approach that produced a closed back, honeycomb- cored mirror weighing less than 18 kg. Details of the mirror design and of the assembly for HIPing are given. The blank was HIPed, leached, and machined to final shape with all design goals met. The as-HIPed blank was within +/- 0.5 mm in all dimensions and the radius of curvature was within 0.2 of target. The mirror was loose-abrasive ground using plunge grinding with a full-size tool, then polished using a full-size flexible pitch lap. In-process metrology utilized a special-purpose swing-arm profilometer with demonstrated accuracy and repeatability of
A program to fabricate a large, optically fast, aspheric lightweight Be mirror has demonstrated state-of-the-art technology. The mirror blank was fabricated as a 1.0-m diameter, f/0.58 ellipse, directly from IP-70 grade powder, using near-net-shape HIPing as well as a patented tooling approach that produced a closed back, honeycomb-cored mirror weighing less than 18 kg. Details of the mirror design and of the assembly for HIPing are given. The blank was HIPed, leached and machined to final shape with all design goals met; as-HIPed, the blank was within +/- 0.5-mm in all dimensions, and the radius of curvature was within 0.2 percent of target. The mirror was loose-abrasive ground using plunge grinding with a full-size tool, then rough polished using a full-size flexible pitch lap. In-process metrology used a special swing-arm profilometer with demonstrated accuracy and repeatability below one micron.
The choice of a substrate material for large mirrors is a complex engineering task that must account for structural and thermal properties as well as mirror blank fabricability polishability and surface scatter. Nuclear hardness is also a consideration in some applications. Cost is almost always a concern. The standard material for mirror substrates has always been glass. Beryllium technology however is well developed and offers distinct advantages over glass in many applications. Reaction-bonded silicon carbide is a relatively new material that has matured to the point where it can now be considered as an alternative to either beryllium or glass in some large optics applications. The availability of these three different substrate materials offers the system designer a great deal of flexibility in optimizing the material for each particular application. In this paper we present a methodology for comparing the structural properties of mirror substrate materials and lightweighting designs. This methodology is used to compare glass beryllium and silicon carbide. 1. LIGHTWEIGHT MIRROR DESIGN PARAMETERS Basic lightweight mirror design parameters are illustrated in Figure 1. Sandwich mirrors comprise two faceplates with a structured core in between. Although the faceplates are shown as having equal thicknesses tf they can in general be unequal. Open-back mirrors have a single faceplate. For both sandwich and open-back mirrors the mirror core is characterized by its height hc the web thickness tw of the core elements
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.