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NASA NTRS2011

From X-Ray Telescopes to Neutron Focusing

In the case of neutrons the refractive index is slightly less than unity for most elements and their isotopes. Consequently, thermal and cold neutrons can be reflected from smooth surfaces at grazing-incidence angles. Hence, the optical technologies developed for x-ray astronomy can be applied for neutron focusing. The focusing capabilities of grazing incidence neutron imaging optics have been successfully demonstrated using nickel mirrors. The mirrors were fabricated using an electroformed nickel replication process at Marshall Space Flight Center. Results of the neutron optics experiments will be presented. Challenges of the neutron imaging optics as well as possible applications of the optics will be discussed.

Gubarev, M. V.↗

NASA NTRS2003

Miniature Inchworm Actuators Fabricated by Use of LIGA

Miniature inchworm actuators that would have relatively simple designs have been proposed for applications in which there are requirements for displacements of the order of microns or tens of microns and for the ability to hold their positions when electric power is not applied. The proposed actuators would be members of the class of microelectromechanical systems (MEMS), but would be designed and fabricated following an approach that is somewhat unusual for MEMS. Like other MEMS actuators, the proposed inchworm actuators could utilize thermoplastic, bimetallic, shape-memory-alloy, or piezoelectric actuation principles. The figure depicts a piezoelectric inchworm actuator according to the proposal. As in other inchworm actuators, linear motion of an extensible member would be achieved by lengthening and shortening the extensible member in synchronism with alternately clamping and releasing one and then the other end of the member. In this case, the moving member would be the middle one; the member would be piezoelectric and would be shortened by applying a voltage to it. The two outer members would also be piezoelectric; the release of the clamps on the upper or lower end would be achieved by applying a voltage to the electrodes on the upper or lower ends, respectively, of these members. Usually, MEMS actuators cannot be fabricated directly on the side walls of silicon wafers, yet the geometry of this actuator necessitates such fabrication. The solution, according to the proposal, would be to use the microfabrication technique known by the German acronym LIGA - "lithographie, galvanoformung, abformung," which means lithography, electroforming, molding. LIGA involves x-ray lithography of a polymer film followed by selective removal of material to form a three-dimensional pattern from which a mold is made. Among the advantages of LIGA for this purpose are that it is applicable to a broad range of materials, can be used to implement a variety of designs, including those of structures >1 mm high, affords submicron precision, and is amenable to mass production at relatively low unit cost. Fabrication of the proposed actuators would involve some technological risks - in particular, in the integration of electrode connection lines and placement of actuator elements. It will also be necessary to perform an intensive study of the feasibility of growing piezoelectric crystals onto LIGA molds.

Yang, Eui-Hyeok↗

NASA NTRS2003

Inverse Tomo-Lithography for Making Microscopic 3D Parts

According to a proposal, basic x-ray lithography would be extended to incorporate a technique, called inverse tomography, that would enable the fabrication of microscopic three-dimensional (3D) objects. The proposed inverse tomo-lithographic process would make it possible to produce complex shaped, submillimeter-sized parts that would be difficult or impossible to make in any other way. Examples of such shapes or parts include tapered helices, paraboloids with axes of different lengths, and even Archimedean screws that could serve as rotors in microturbines. The proposed inverse tomo-lithographic process would be based partly on a prior microfabrication process known by the German acronym LIGA (lithographie, galvanoformung, abformung, which means lithography, electroforming, molding). In LIGA, one generates a precise, high-aspect ratio pattern by exposing a thick, x-ray-sensitive resist material to an x-ray beam through a mask that contains the pattern. One can electrodeposit metal into the developed resist pattern to form a precise metal part, then dissolve the resist to free the metal. Aspect ratios of 100:1 and patterns into resist thicknesses of several millimeters are possible.

White, Victor↗

NASA NTRS2012

Single-Layer, All-Metal Patch Antenna Element with Wide Bandwidth

It is known that the impedance at the center of a patch antenna element is a short circuit, implying that a wire or post can be connected from the patch to the groundplane at this point without impacting radiation performance. In principle, this central post can be used to support the patch element, thus eliminating the need for dielectric. In spaceborne applications, this approach is problematic because a patch element supported by a single, thin post is highly susceptible to acoustic loads during launch. The technology reported here uses a large-diameter center post as its supporting structure. The supporting structure allows for the fabrication of a sufficiently rigid antenna element that can survive launch loads. The post may be either hollow or solid, depending on fabrication approach and/or mass constraints. The patch antenna element and support post are envisioned as being fabricated (milled) from a single piece of aluminum or other metal. Alternately, the patch plate and support column can be fabricated separately and then joined using fasteners, adhesive, or welding. Casting and electroforming are also viable techniques for manufacturing the metal patch part(s). The patch structure is then either bonded or fastened to the supporting groundplane. Arrays of patch elements can be fabricated by attaching several structures to a common groundplane/support structure.

Chamberlain, Neil F.↗

NASA NTRS2012

Flight Programs and X-ray Optics Development at MSFC

The X-ray astronomy group at the Marshall Space Flight Center is developing electroformed nickel/cobalt x-ray optics for suborbital and orbital experiments. Suborbital instruments include the Focusing X-ray Solar Imager (FOXSI) and Micro-X sounding rocket experiments and the HERO balloon payload. Our current orbital program is the fabrication of a series of mirror modules for the Astronomical Roentgen Telescope (ART) to be launched on board the Russian-German Spectrum Roentgen Gamma Mission (SRG.) The details and status of these various programs are presented. A second component of our work is the development of fabrication techniques and optical metrology to improve the angular resolution of thin shell optics to the arcsecond-level. The status of these x-ray optics technology developments is also presented.

Gubarev, M.↗

NASA NTRS2015

X-Ray Optics at NASA Marshall Space Flight Center

NASA's Marshall Space Flight Center (MSFC) engages in research, development, design, fabrication, coating, assembly, and testing of grazing-incidence optics (primarily) for x-ray telescope systems. Over the past two decades, MSFC has refined processes for electroformed-nickel replication of grazing-incidence optics, in order to produce high-strength, thin-walled, full-cylinder x-ray mirrors. In recent years, MSFC has used this technology to fabricate numerous x-ray mirror assemblies for several flight (balloon, rocket, and satellite) programs. Additionally, MSFC has demonstrated the suitability of this technology for ground-based laboratory applications-namely, x-ray microscopes and cold-neutron microscopes and concentrators. This mature technology enables the production, at moderately low cost, of reasonably lightweight x-ray telescopes with good (15-30 arcsecond) angular resolution. However, achieving arcsecond imaging for a lightweight x-ray telescope likely requires development of other technologies. Accordingly, MSFC is conducting a multi-faceted research program toward enabling cost-effective production of lightweight high-resolution x-ray mirror assemblies. Relevant research topics currently under investigation include differential deposition for post-fabrication figure correction, in-situ monitoring and control of coating stress, and direct fabrication of thin-walled full-cylinder grazing-incidence mirrors.

X-ray Optics↗

NASA NTRS2015

SuperHERO: Design of a New Hard X-Ray Focusing Telescope

SuperHERO is a hard x-ray (20-75 keV) balloon-borne telescope, currently in its proposal phase, that will utilize high angular-resolution grazing-incidence optics, coupled to novel CdTe multi-pixel, fine-pitch (250 micrometers) detectors. The high-resolution electroformed-nickel, grazing-incidence optics were developed at MSFC, and the detectors were developed at the Rutherford Appleton Laboratory in the UK, and are being readied for flight at GSFC. SuperHERO will use two active pointing systems; one for carrying out astronomical observations and another for solar observations during the same flight. The telescope will reside on a light-weight, carbon-composite structure that will integrate the Wallops Arc Second Pointer into its frame, for arcsecond or better pointing. This configuration will allow for Long Duration Balloon flights that can last up to 4 weeks. This next generation design, which is based on the High Energy Replicated Optics (HERO) and HERO to Explore the Sun (HEROES) payloads, will be discussed, with emphasis on the core telescope components.

SuperHERO↗

NASA NTRS2015

Grazing Incidence Optics Technology

This project is to demonstrate the capability to directly fabricate lightweight, high-resolution, grazing-incidence x-ray optics using a commercially available robotic polishing machine. Typical x-ray optics production at NASA Marshall Space Flight Center (MSFC) uses a replication process in which metal mirrors are electroformed on to figured and polished mandrels from which they are later removed. The attraction of this process is that multiple copies can be made from a single master. The drawback is that the replication process limits the angular resolution that can be attained. By directly fabricating each shell, errors inherent in the replication process are removed. The principal challenge now becomes how to support the mirror shell during all aspects of fabrication, including the necessary metrology to converge on the required mirror performance specifications. This program makes use of a Zeeko seven-axis computer-controlled polishing machine (see fig. 1) and supporting fabrication, metrology, and test equipment at MSFC. The overall development plan calls for proof-of-concept demonstration with relatively thick mirror shells (5-6 mm, fig. 2) which are straightforward to support and then a transition to much thinner shells (2-3 mm), which are an order of magnitude thinner than those used for Chandra. Both glass and metal substrates are being investigated. Currently, a thick glass shell is being figured. This has enabled experience to be gained with programming and operating the polishing machine without worrying about shell distortions or breakage. It has also allowed time for more complex support mechanisms for figuring/ polishing and metrology to be designed for the more challenging thinner shells. These are now in fabrication. Figure 1: Zeeko polishing machine.

Ramsey, Brian↗

NASA NTRS2018

X-Ray Optics Development at NASA MSFC

Outline: X-ray optics for space-borne applications; Electroformed NiCo X-ray optics at MSFC (Marshall Space Flight Center); Thin film coatings to enhance X-ray optical performance; Thin film stress; In-situ film stress measurement at MSFC: from prototype to refined design; Ultra lightweight aerogel mirrors.

X-Ray Optics↗

NASA NTRS2019

Deterministic Polishing of Replicating Grazing-Incidence Mandrels

In an effort to manufacture high-angular-resolution, grazing-incidence, x-ray optics, Marshall Space Flight Center (MSFC) is taking measures to improve its electroformed replicated optics. A key development is the use of computer-numerical control (CNC) polishing to deterministically improve the surface of electroless nickel mandrels used to replicate grazing- incidence optics. Metrology, control software and polishing parameters must function together seamlessly to reach the specifications required to replicate sub-arcsecond optics. Each change in polishing parameters effects the wear pattern of the polishing head. Using Richardson-Lucy deconvolution, the controller software fits the wear pattern to metrology data to calculate the changing feedrates across the mandrel. Here we present an overview of our process, and early results showing the effectiveness of deterministic polishing for replicated optics.

Davis, Jacqueline↗

NASA NTRS2020

OSA Spotlight Summary: Designing Miniature X-ray Optics for the SmallSat Lunar Science Mission Concept CubeX

The scientific demand for extended field X-Ray remote sensing for mapping of planetary bodies has produced the CubeSat X-ray Telescope (CubeX) lunar mission concept. Orbiting the Moon at 6,000 km for 1 year sometime during the mid-decade solar maximum, the primary objectives of CubeX are to map lunar surface elemental abundances and to assess feasibility of x-ray pulsar timing navigation. CubeX’s Miniature X-ray Optics (MiXO) design builds on heritage of existing X-ray imaging designs using new electroformed NiCo alloy replication (ENR) to create shells of 1 mm thickness. MiXO will provide 1 arcmin resolution X-Ray imaging for an extended instantaneous field of view, at various energy range sensitivities. Based on the classic Wolter-Type I design (using a paraboloid/hyperboloid grazing mirror pair), mirror parameters were expanded to allow both shell length and focal-plane offsets to vary independently. The design was optimized with a merit function that factored together four sub-merits: PSF sharpness (measured as half-power diameter), consistency across the field, minimized scattering, and maximized effective area. Monte Carlo analysis was used to predict final performance, including surface scatter effects. The demonstrated configurations include a compact 34 shell design with a diameter of 105 mm more efficient at higher energies, and a larger 130 mm/24 shell version with a larger overall effective area at lower energies. The compact design carries more expensive fabrication and assembly cost (with more shells) as well as a more challenging alignment (with denser packing). Both have overall resolution <1’ up to 26’ off-axis and <1.5’ up to 33’ off-axis, whereas a conventional design’s image quality degrades quickly beyond 15’ off-axis. This opens up new possibilities for future SmallSat missions that could use two different configurations for wide energy ranges or midsized instruments using multiple identical modules for larger collecting area.

x-ray↗

NASA NTRSDate not supplied

Toward the fabrication of a 5 μm resolution Wolter microscope for the National Ignition Facility

Advancements in computer-controlled polishing, metrology, and replication have led to a x-ray mirror fabrication process that is capable of producing high-resolution Wolter microscopes. The mirror is a nickel-cobalt replicated full-shell mirror that was electroformed from a finely figured and polished mandrel. This mandrel was designed and fabricated for a 8 m source-to-detector distance microscope, with 10× magnification. A computer controlled polishing process corrected the low-frequency mandrel figure to < 2.0 nm RMS error. The mandrel design was optimized to reduce shell distortions that occur mainly < 20 mm from the shell ends. This design, in combination with improved replication tooling design and refined bath parameters informed by a detailed COMSOL model, have led to reductions in replication errors in the mirror shell. X-ray tests performed on a pair of mirror shells replicated from the mandrel have demonstrated < 10 μm FWHM source plane imaging resolution. Here we discuss the development process, highlight results from metrology and x-ray testing, and define a path for achieving 5 μm FWHM resolution.

Grazing Incidence, Wolter Microscope, X-ray Optics↗