Low Cost Very Large Diamond Turned Metal Mirror! Mirror Technology SBIR/STTR Workshop June 20 th to 23 rd, 2011 Greenbelt Marriott, Greenbelt, Md.
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1 Low Cost Very Large Diamond Turned Metal Mirror! Contract No. NNX10CB49C (SBIR 08-2 S ) (MSFC)! Mirror Technology SBIR/STTR Workshop June 20 th to 23 rd, 2011 Greenbelt Marriott, Greenbelt, Md. John M. Casstevens! Dallas Optical Systems, Inc.! ! These SBIR data are furnished with SBIR rights under Contract No.NNX10CB49C. For a period of 4 years, unless extended in accordance with FAR (h), after acceptance of all items to be delivered under this contract, the Government will use these data for Government purposes only, and they shall not be disclosed outside the Government (including disclosure for procurement purposes) during such period without permission of the Contractor, except that, subject to the foregoing use and disclosure prohibitions, these data may be disclosed for use by support Contractors. After the protection period, the Government has a paid-up license to use, and to authorize others to use on its behalf, these data for Government purposes, but is relieved of all disclosure prohibitions and assumes no liability for unauthorized use of these data by third parties. This notice shall be affixed to any reproductions of these data, in whole or in part. Distribution A: Approved for Public Release, Distribution is Unlimited. Mirror Technology Workshop June 22,
2 Low Cost Very Large Diamond Turned Metal Mirror! Contract No. NNX10CB49C (SBIR 08-2 S ) (MSFC)! OUTLINE! CONCEPT AND GOALS! MIRROR MFG. PROCESS! PROGRESS TO DATE! SUMMARY! Mirror Technology Workshop June 22,
3 Concept and Goals --- Develop and demonstrate a process for producing a light weight,! stiff mirror substrate by electroplating a NiP alloy over a plastic foam mandrel which will be removed with solvent after plating.! --- Demonstration of diamond turning as a method of producing a! high quality optical surface on the electroplated NiP substrate by producing a 300 mm (12 inch) diameter flat test mirror and a 600mm (24 inch) flat mirror.! --- Optical inspection of the finished mirrors to evaluate mechanical stability and stiffness and the extent of mirror internal structure print through on the finished optical surface as a function of faceplate thickness.! --- Optical and dimensional inspection and characterization of the finished mirror for overall optical figure accuracy and surface! smoothness achieved by diamond turning. Mirror Technology Workshop June 22,
4 Electroform NiP tubes with the required length and diameter and with one end closed and the other open.! Machine plastic foam to desired shape of substrate master. With press-fit holes for NiP tubes which go completely thru the foam master.! MIRROR MFG. PROCESS! Install electroformed tubes in foam master so that the ends of the tubes are flush with the optical contour of the foam master.! Seal and coat plastic master with electrically conductive thin film to allow electroplating.! Electroplate the master and inserted tubes to completely encapsulate the assembly; joining the tubes to the front and back surfaces to form a stiff, continuous NiP structure.! Drill access holes through the NiP skin to allow introduction of solvent.! Use solvent such as acetone to dissolve the plastic master and leave only a mirror substrate of electroplated NiP alloy.! Diamond turn the exterior of the NiP mirror substrate to produce the desired optical contour and mounting and reference surfaces.! Optical inspection of the finished mirror.! Mirror Technology Workshop June 22,
5 Weight of 1 Sq. Meter Mirror! Mirror Technology Workshop June 22,
6 Off-Axis Aspheric Mirror! Mirror Technology Workshop June 22,
7 1.8 Meter Diameter Foam Plastic Mirror Substrate! Mirror Technology Workshop June 22,
8 2.48 Meter Aluminum Mirror! Mirror Technology Workshop June 22,
9 Large Part Diamond Turning Experience! Mirror Technology Workshop June 22,
10 Technology A very important enabling process for plating high phosphorus nickel alloys using an electrolytic process has been developed at the University of Alabama at Huntsville and at Marshall Space Flight Center. This plating process has been demonstrated to be capable of producing very low stress deposits of very high quality that allow excellent surfaces to be diamond turned on the NiP deposit. The electrolytic NiP plating process is not limited in plating thickness. Thick wall, structurally robust mirror substrates can be built up with this electroplating process. Mirror Technology Workshop June 22,
11 Mirror Technology Workshop June 22,
12 Electroforming Technology Developed by UAH and MSFC! for X-Ray Telescope Fabrication! Mirror Technology Workshop June 22,
13 0.3 Meter PLASTIC FOAM MIRROR FORM! Mirror Technology Workshop June 22,
14 MIRROR DESIGN! Plating thicknesses and diameter and spacing of tubes optimized for best performance.! Mirror Technology Workshop June 22,
15 89mm DIAMETER FOAM MASTER FORMS! Mirror Technology Workshop June 22,
16 NiP Plated 89mm Mirror Substrate Assembly! Mirror Technology Workshop June 22,
17 Precision Machined Back of Plated Mirror Assembly! Mirror Technology Workshop June 22,
18 Diamond Turned and Polished NiP Mirror! Mirror Technology Workshop June 22,
19 SBIR GOAL IS A LOW COST PROCESS FOR 3 MT. MIRRORS! CLOSED END ELECTROFORMS ARE NOT PRACTICAL! Large mirrors require production of thousands of tubes.! Curved mirrors require tubes of different lengths.! Large production of tubes of many lengths not cost effective.! PRODUCTION FRIENDLY METHOD FOR ELECTROFORMED TUBES! Electroform long tubes and cut to required lengths.! Open end tubes allow holes in foam to be parallel to optical axis.! Inserted electroformed tube assemblies can be matched to contour.! Removal of mandrels from electroformed mirrors must be reliable.! Chose acrylic rod mandrel removed by differential shrinkage.! Mirror Technology Workshop June 22,
20 SULFAMATE NICKEL PLATED ACRYLIC PLASTIC RODS CUT TO MATCH STYRENE FOAM! Mirror Technology Workshop June 22,
21 175 mm Diameter Polystyrene Foam Mandrels! Mirror Technology Workshop June 22,
22 ISSUES FOR ELECTROFORMING TUBES ON RODS! Cutting composite of hard nickel on soft rod is difficult.! Polymer rod must be smooth, round and constant diameter.! Polymer must allow reliable mandrel removal from mirror substrate.! Nickel Phosphorus is a hard, strong and brittle material.! Removal of mandrels must be a low force process.! Electrically conductive coatings on polymer must be reliable.! Mirror Technology Workshop June 22,
23 Acrylic Rod Removed From Test Mirror By Differential Shrinkage! Mirror Technology Workshop June 22,
24 Test Mirror Cut in Half for Evaluation of Joint Quality! Mirror Technology Workshop June 22,
25 Micrographs of Unreliable Tube to Mirror Face Joint! FRONT FACE! BACK FACE! Mirror Technology Workshop June 22,
26 HIGH QUALITY JOINT STRENGTH AT TUBE ENDS! Continued development of plating methods on polymers.! Rough DT of NiP substrate to expose ends of mandrels.! Electroformed tubes must be machineable with diamond.! Ductile sulfamate nickel is not compatible with diamond tools.! Only one material means low thermal distortion.! More testing to develop methods of addressing these problems.! Use one tube in 80mm diameter foam mandrels for tests.! Mirror Technology Workshop June 22,
27 Test Mirror Assemblies With Nickel Plated Acrylic Rod! Mirror Technology Workshop June 22,
28 Four Test Mirror Substrates After NiP Plating! Mirror Technology Workshop June 22,
29 Test Mirror Cut in Half for Evaluation of Joint Quality! Mirror Technology Workshop June 22,
30 High Quality NiP Plated Test Mirror Substrate! Mirror Technology Workshop June 22,
31 Diamond Turned and Polished NiP Test Mirror! Mirror Technology Workshop June 22,
32 MANDREL DEVELOPMENT! Low cost composite mandrel material for electroplating of NiP.! Easier faster cutting of plated rods to required length.! Castable mandrel material is recycleable low cost and low waste.! Composite tube mandrel allows mandrel removal by differential! thermal expanision, melting and dissolution.! New mandrel for electroplating meets SBIR goal of very low! cost of large mirror substrates.! Currently using composite tube mandrel material for mirror tests.! Mirror Technology Workshop June 22,
33 NiP Plated Composite Tube Assemblies! Mirror Technology Workshop June 22,
34 SUMMARY! Low Cost Mirror SUBSTRATE by Electroplating of NiP.! Diamond Turning & Post Polish of NiP Electroformed Substrate.! Low Cost Very Flexible Manf. Process for Large Mirrors.! Low (10-30 Kg/Sq. Meter) Areal Density, Very stiff metal mirror.! Only one material means low thermal distortion.! Currently using composite tube mandrel which allows mandrel! removal by thermal expansion, melting and dissolution.! Mirror Technology Workshop June 22,
Low Cost Very Large Diamond Turned Metal Mirror Contract No. NNX09CF40P (SBIR ) (MSFC)
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