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Electroform welding used to join variety of parts without addition of detrimental heat. Technique developed so large and/or complexly shaped parts joined without degrading properties of materials. Commercial uses include joining dissimilar alloys. Beneficial for suppression of distortion or maintenance of close tolerances in precise components.
This task is in support of the Quiet Hypersonic Wind Tunnel effort currently in effect at NASA Langley Research Center, VA. A laminar flow wind tunnel nozzle has been previously fabricated by electroforming pure nickel over a machined and polished two piece stainless steel mandrel. The mandrel was removed leaving the replicate nozzle surface. The nozzle was then pressed into a heavy stainless steel jacket for mounting features and rigidity. The original nickel surface was a replication of the polished mandrel but had degraded due to oxidation. The inside surface requirements are very stringent in order to achieve laminar or quiet flow at the desired pressure and temperature for the specific design of Mach 5. The throat area of the axisymmetric device must have a surface finish with no defects greater than 16 microinches. This requires an rms average background of about four microinches or better for inspection purposes. A coating of nickel-phosphorous alloy was applied by catalytic deposition and then the inside of the nozzle was polished retaining dimensional and surface finish tolerances as specified per drawings supplied. Since the unit is not an optical component, conventional optical inspection methods for surface finish and figure are not readily achieved. Measurements were made using surface profilometry.
This paper summarizes the work to date on a novel mirror fabrication technique being developed at the Marshall Space Flight Center for potential use on the Next Generation Space Telescope (NGST). This technique involves forming an extremely lightweight mirror by electroplating nickel and nickel based alloys onto a highly polished precision mandrel. The resulting mirror shell can then be backed up with or attached to a lightweight structure to produce a mirror element that is on the order of 15 kg/sq m areal density. Since the mirrors are fabricated from a mandrel (or master), subsequent mirrors can be made with very high economy; this technique is particularly suited to segmented mirrors schemes whereby large apertures are achieved through the deployment of smaller segments. Control of the electroplating process is the key element for producing high quality optics; bath chemistry and real time control of the plating current density yields uniform grained electroforms with zero residual stress. To accomplish this, a special electronic sensor was developed whereby the residual stress can be monitored as the nickel is electrolytically deposited. This information is used in a feedback loop to modulate current density which, in turn, directly governs the residual stress. Details pertaining to this and other aspects of the fabrication of a half meter mirror will be published along with test results and metrology data.
Replicated electroformed light-weight nickel alloy mirrors can have high strength, low areal density (<3kg/m2), smooth finish, and controllable alloy composition. Progress at NASA MSFC SOMTC in developing normal incidence replicated Nickel mirrors will be reported.
Replicated electroformed light-weight nickel alloy mirrors can have high strength, low areal density (less than 3kg/m2), smooth finish, and controllable alloy composition. Progress at NASA MSFC SOMTC in developing normal incidence replicated Nickel mirrors will be reported.
We are developing the nickel electroforming process to fabricate high-quality mirrors for the region. Two applications for these optics are a balloon-borne payload, termed HERO, and a hard-X-ray telescope module for consideration for the Constellation-X mission. In the formation on shells, of 15 arcsec angular resolution, will provide over 200 sq cm of effective collecting area unprecedented sensitivity in the 20-75 keV region. A first flight of a partial payload, feature approximately 1/4 of the total collecting area, is scheduled for the Spring of 2004. In the Co-application, two mirror shells, of diameters 150 and 230 mm, are being fabricated. This is particularly challenging as high angular resolution must be maintained with shells of only 1 mm thickness (driven by the tight weight budget for the mission). Further, the shells must be low (less than 5 A on sub-micron spatial scales) to permit efficient use of planned multilayer coatings which must release cleanly from their forming mandrels without any surface degradation.
This slide presentation reviews the developments at Marshall Space Flight Center in fabricating Electroformed Nickel X-ray Optical devices. Missions that are using the mandrels created using the described process are reviewed, and improvements in the process of creating better quality mandrels are also reviewed. One of the processes, Electrochemically-Enhanced Mechanical Polishing (EEMP), is described. The Alignment and mounting system for full-shell replicated X-Ray Optics is shown, and the selective deposition process is also shown.
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Explore the source record for details and available documents.
Explore the source record for details and available documents.
Optical and calorimetric tests of nickel mirrors for use as power source for thermionic generators
The utilization of a digital computer to augment electrodeposition/electroforming processes in which nonconducting shielding controls local cathodic current distribution is reported. The primary underlying philosophy of the physics of electrodeposition was presented. The technical approach taken to analytically simulate electrolytic tank variables was also included. A FORTRAN computer program has been developed and implemented. The program utilized finite element techniques and electrostatic theory to simulate electropotential fields and ionic transport.
Special procedures were developed and then utilized for plating nickel over channels of a throat nozzle section of a NASA Langley combustor facility. When tested hydrostatically, the part failed in the stainless-steel substrate and not at the interface between the plating and substrate. The procedures used for plating the part are detailed as are high-temperature property data which show that the part can withstand long-term, high-temperature exposure without suffering degradation of the plated bond.
Copper electrodes replace graphite electrodes in many instances of electrical-discharge machining (EDM) of complex shapes. Copper electrodes wear longer and cause less contamination of EDM dielectric fluid than do graphite electrodes.
A design for a mirror array telescope for high energies with almost 1000 sq cm effective area at 7 keV is described. Briefly, it consists of 36 modules. Each module contains Wolter I mirrors nested 6 deep. The system is small enough to be flown on an Aries rocket. With the current mirrors, the angular resolution at high contrast is 20 arcsec and the half power diameter for images is 1.5 arcmin at 1.5 keV and 3.5 arcmin - 4 arcmin at 7 keV. Plans to improve upon this performance are discussed.
The task objective has been to apply a coating of nickel-phosphorous alloy to a laminar flow wind tunnel nozzle by catalytic deposition and then polish and inspect the inside surface using optical device processes. The surface of the nozzle was coated with a nickel-phosphorous alloy of sufficient hardness and corrosion resistance to improve the durability. Due to plating defects that were clearly process related and not inherent, the final polished part was less than the desired quality. Surface finishing processes and lapping media were identified which produced a submicron surface finish on the interior plated surface. Defects apparently manifested by the first plating attempt were repaired using a small brush plating process demonstrating that individual small defects can be repaired. Measurement and analysis by profilometry demonstrated that quantitative control of the surface can be achieved.
A sapphire master was used to produce mirrors that exhibit mid-to-high-frequency roughness as low as 3 A. The fabrication procedure and potential applications in X-ray astronomy are discussed. It is shown that foils replicated from flat smooth mandrels should offer at least equivalent HF roughness and significantly lower mid-frequency ripple than those coated with lacquer. A ceramic-surface mandrel could also be expected to last far longer without the need for repolishing than electroless nickel-coated mandrels.
One contribution in reducing the costs of optics in space can be provided by production of ultralight mirrors. The decrease in the weight of the primary mirror of a telescope is anticipated to lead to the possibility of increasing the size of the telescopes, therefore increasing the amount and distance from which information is received. An electroplating process of ultralight replica mirrors from nickel sulfamate solution will be described. Based on an experimental setup with cylindrical symmetry, flat mirrors with a diameter of 7 inches and thickness of 1.5 mm are made from a Ni-Co alloy. The composition of the resulting deposit is analyzed using Rutherford Backscattering Spectrometry (RBS) and Proton Induced X-ray Emission (PIXE). In order to resolve Ni and Co, 10 MeV nitrogen ions are used as projectiles in the RBS measurements. Solution parameters monitored during the deposition process using optical absorption and polarography will be correlated with the final concentration of Ni and Co in the deposit. Bath parameters like temperature, current density, agitation level and acidity are chosen at certain values and maintained constant from one sample to another throughout the deposition process. The purpose of the experiment is to obtain mirrors with near zero stress, and predetermined composition and hardness. This study is an intermediate step in obtaining through the same process, but with a larger scale setup, ultralight large aperture replica mirrors.