NASA NTRS2001
We describe the fabrication process for producing high-resolution conical mirrors for hard x-ray astronomy. When flown aboard stratospheric balloons, these high-resolution reflective mirrors focus hard x-rays (10-70 keV) emitted from cosmic sources such as supernovae, neutron stars, and quasars onto imaging focal plane detectors. Focused hard x-ray images allow scientists to determine the elemental compositions, temperatures, magnetic fields, velocities, and gravitational fields of these celestial bodies. The fabrication process involves generating super-polished mandrels, mandrel metrology, mirror shell nickel electroforming, and mirror testing. Each mandrel is a cylinder consisting of two conical segments; each segment is approximately 305-mm long. Through precision grinding these mandrels before super polishing, we have achieved 30 arc seconds, half power diameter replicated mirrors. During a May 2001 high atmosphere balloon flight, these mirrors focused high energy x-rays from three different celestial sources. However, we seek to improve the angular resolutions of future mirror shells by a factor of two. To achieve this goal, we have begun single point diamond turning the mandrels before super polishing. This has allowed greater precision tolerances on mandrel surface roughness and axial figure errors before super polishing. Surface roughnesses before polishing have been reduced from approximately 60 nm to approximately 15 nm. The peak to valley axial figure profile errors have been reduced from approximately 1.0 micrometers to approximately 0.4 micrometers. We are currently in Phase 2 of the HERO (high energy replicated optics) program which entails the production of sixteen 6-m-focal-length mirror modules, each containing a nested array of 15 mirror shells of diameters ranging from 50-mm to 94-mm. This flight is slated for the fall of 2003.