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At least 127 records · Page 7

Making Thin Sections from National Treasures: A Little Moon Rock Goes a Long Way

NASA’s Johnson Space Center curates the Apollo sample collection through their facilities in Houston, TX. It is a dual-purpose facility, intended both to store and preserve the precious samples, as well as to make them available for ongoing scientific study and public examination. The facilities consist of multiple vaults and lab spaces, including the Apollo Thin Section Lab. Although it is a part of the Curation facilities, this lab is intended to process specific lunar rock and dust samples into what are called “thin sections”. A thin section is a microscope slide with a very thin, highly polished slice of rock material mounted on it. These are used not only for microscope viewing, but also for a range of other sophisticated scientific instruments to map and measure fine details of the rock’s physical and chemical composition and structure. The process of making a thin section requires great care and patience and is an art in itself; each one is unique, and each sample can behave very differently while going through the same basic procedures. In general, it begins by taking a small chip of rock from a much larger sample. The rock fragment is placed within a small mold and liquid epoxy is poured over it and allowed to harden, producing what is called a “potted butt” (Figure 1). This is to stabilize the rock so that it won’t fragment or crumble during polishing, and to fill any cracks or voids within the rock. Once hardened, the epoxy on the bottom is carefully ground away to expose the rock surface within, which is then polished to a 1-micron finish. A thin new layer of fresh epoxy is then applied to the polished surface and used to mount it to a silica slide. Once the mounting epoxy has hardened, the potted butt is cut off less than one millimeter above the slide using a low-speed circular saw. This thin layer of sample material attached to the slide undergoes further grinding and polishing, typically bringing the sample thickness down to about 35 microns – roughly one third of the thickness of a human hair. The remaining potted butt is saved for future scientific investigations and can be re-polished and used again until all the rock material within it is used up. A single thin section can be reused countless times by numerous different researchers. In addition, thin sections are often exquisitely beautiful (Figure 2) and in some cases, lunar thin sections are used as public display samples, such as at the Smithsonian Air and Space Museum in Washington, DC. The production of thin sections allows an immense variety of research to be conducted on a tiny amount of rock or mineral material, allowing the bulk of the Apollo collection to stay pristine and unaltered, and thus, remain available for next generation of lunar scientists to further our insight into the Moon’s geological diversity, and to bring valuable new insights to our understanding of the origin of the Earth-Moon system.

J J Kent↗

Fatigue behavior of two alloys for Space Shuttle applications

Two superalloys used extensively in the Space Shuttle main engine are Incoloy 903 and Inconel 718. The fatigue behavior of the two alloys under varying conditions is considered. Three heats of Incoloy 903 and two of Inconel 718 were used in the study. Material was tested in several conditions, including mill polish, longitudinal mill polish, transverse mill polish, chemically milled, chemically milled plus shotpeened on one side and on both sides, gas tungsten arc welded, and electron beam welded. Both round and flat tensile specimens were tested in universal test machines. It was found that surface condition influences test results. Transverse scratches resulting from polishing and rougher surfaces lower the stress at runout in relation to that obtained on longitudinally polished and/or smooth-surfaced specimens.

Adsit, N. R.↗

Readying advanced composites for the microscope

Concerns related to the proper preparation of composite specimens for microstructural analysis are examined. Proper preparation will minimize the amount of surface and subsurface damage at each stage of the procedure so that the microstructural features of the final-polished specimen can be accurately determined as a function of the composite's response to processing, testing, or service conditions. This requires that an optimum combination of abrasive type, size, and bond be applied during each grinding, lapping, and polishing step. Machine settings, such as polishing speed, force, and relative polishing direction, are also important. Guidelines are given for each step of the six-stage specimen preparation process: sectioning, planar grinding, sample integrity, polishing, and etching.

Zipperian, Donald C.↗

Neutral Ion Figuring of Chemical Vapor Deposited SiC

Ion figuring of optical components is a relatively new technology that can alleviate some of the problems associated with traditional contact polishing. Because the technique is noncontacting, edge distortions and rib structure print through do not occur. This investigation was aimed at determining the effect of ion figuring on surface roughness of previously polished or ductile ground ceramic optical samples. This is the first step in research directed toward the combination of a prefinishing process (ductile grinding or polishing) with ion figuring to produce finished ceramic mirrors. Multiple, chemical vapor deposited silicon carbide (CVD SiC) samples were polished or ductile ground to specular or near-specular roughness. These samples were then characterized to determine topographic surface information. The surface evaluation consisted of stylus profilometry, interferometry, and optical and scanning electron microscopy. The surfaces were then ion machined to depths from 0 to 5 micron. The finished surfaces were characterized to evaluate the effects of the ion-machining process with respect to the previous processing methods and the preexisting subsurface damage. This study provides some of the information required to effectively utilize a combined ductile grinding or polishing with ion machining as a procedure for figuring optical components.

Fawcett, Steven C.↗

Fabricating High Resolution Mirrors for Hand X-Ray Astronomy

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.

Speegle, Chet O.↗

Method of fabricating a whispering gallery mode resonator

A method of fabricating a whispering gallery mode resonator (WGMR) is provided. The WGMR can be fabricated from a particular material, annealed, and then polished. The WGMR can be repeatedly annealed and then polished. The repeated polishing of the WGMR can be carried out using an abrasive slurry. The abrasive slurry can have a predetermined, constant grain size. Each subsequent polishing of the WGMR can use an abrasive slurry having a grain size that is smaller than the grain size of the abrasive slurry of the previous polishing iteration.

Savchenkov, Anatoliy A.↗

Progress in the Fabrication and Testing of Telescope Mirrors for the James Webb Space Telescope

The telescope of the James Webb Space Telescope (JWST) is an f/20, three mirror anastigmat design, passively cooled (40K) in an L2 orbit. The design provides diffraction limited performance (Strehl > or = 0.8) at .=2 m. To fit within the launch vehicle envelope (Arianne V), the 6.6 meter primary mirror and the secondary mirror support structure are folded for launch, then deployed and aligned in space. The primary mirror is composed of 18 individual, 1.3 meter (flat flat) hexagonal segments, each adjustable in seven degrees of freedom (six rigid body + radius of curvature) provided by a set of high precision actuators. The actuated secondary mirror (approx.0.74m) is similarly positioned in six degrees of rigid body motion. The approx..70x.51m, fixed tertiary and approx. 0.17m, flat fine steering mirror complete the telescope mirror complement. The telescope is supported by a composite structure optimized for performance at cryogenic temperatures. All telescope mirrors are made of Be with substantial light-weighting (21 kg for each 1.3M primary segment). Additional Be mounting and supporting structure for the high precision (approx.10nm steps) actuators are attached to the primary segments and secondary mirror. All mirrors undergo a process of thermal stabilization to reduce stress. An extensive series of interferometric measurements guide each step of the polishing process. Final polishing must account for any deformation between the ambient temperature of polishing and the cryogenic, operational temperature. This is accomplished by producing highly precise, cryo deformation target maps of each surface which are incorporated into the final polishing cycle. All flight mirrors have now completed polishing, coating with protected Au and final cryo testing, and the telescope is on track to meet all system requirements. We here review the measured performance of the component mirrors and the predicted performance of the flight telescope.

Bowers, Charles↗

Factors Affecting the Ductility and Strength of NaCl Single Crystals Tested in Flexure

An experimental investigation has revealed that the initial deformation of NaCl single crystals is anelastic rather than Hookean. This anelastic deformation is manifested by a low slope foot in the load‐deflection curve. The magnitude of the foot is dictated by the pretreatment given the specimen. Treatments which increase or decrease the fresh dislocation density respectively increase or decrease the length of the initial anelastic foot. The order of increasing ductility and strength with specimen pretreatment was found to be (1) heated at 135 C, (2) as cleaved, (3) coated with silver, (4) heated at 135 C and then water polished, (5) water polished and then coated with silver, (6) water polished, (7) water polished and then heated at 135 C, (8) annealed at 700 C, and (9) annealed at 700 C and then water polished. The experimental results have been discussed in terms of the role played in deformation and fracture by surface cracks, grown‐in dislocations, and fresh dislocations.

Stearns, C. A.↗

The design, construction and testing of the optics for a 147-cm-aperture telescope

Geodetic optics research for the Air Force Cambridge Research Laboratories (AFCRL) is described. The work consisted mainly of the fabrication of the optical components for a telescope with a 152-cm-diam (60-in.) primary mirror masked down to 147-cm-diam for use by the AFCRL for a lunar ranging experiment. Among the achievements of this contract were the following: completion of the primary and secondary mirrors for a high-quality 147-cm-diam telescope system in eight months from the start of edging the primary; manufacture and testing of a unique center mount for the primary according to an AFCRL design that allowed for a thin-edged and therefore less-massive mirror; and development of a quantitative analysis of the wire test for calculating the departure of the mirror figure from the design figure quickly and accurately after each polishing step. This analysis method in conjunction with a knowledge of polishing rates for given weights and diameters of tools, mirror, and polishing materials should considerably reduce the polishing time required for future large mirrors.

Buchroeder, R. A.↗

Reliability of void detection in structural ceramics using scanning laser acoustic microscopy

The reliability of scanning laser acoustic microscopy (SLAM) for detecting surface voids in structural ceramic test specimens was statistically evaluated. Specimens of sintered silicon nitride and sintered silicon carbide, seeded with surface voids, were examined by SLAM at an ultrasonic frequency of 100 MHz in the as fired condition and after surface polishing. It was observed that polishing substantially increased void detectability. Voids as small as 100 micrometers in diameter were detected in polished specimens with 0.90 probability at a 0.95 confidence level. In addition, inspection times were reduced up to a factor of 10 after polishing. The applicability of the SLAM technique for detection of naturally occurring flaws of similar dimensions to the seeded voids is discussed. A FORTRAN program listing is given for calculating and plotting flaw detection statistics.

Roth, D. J.↗

Reliability of void detection in structural ceramics by use of scanning laser acoustic microscopy

The reliability of scanning laser acoustic microscopy (SLAM) for detecting surface voids in structural ceramic test specimens was statistically evaluated. Specimens of sintered silicon nitride and sintered silicon carbide, seeded with surface voids, were examined by SLAM at an ultrasonic frequency of 100 MHz in the as fired condition and after surface polishing. It was observed that polishing substantially increased void detectability. Voids as small as 100 micrometers in diameter were detected in polished specimens with 0.90 probability at a 0.95 confidence level. In addition, inspection times were reduced up to a factor of 10 after polishing. The applicability of the SLAM technique for detection of naturally occurring flaws of similar dimensions to the seeded voids is discussed. A FORTRAN program listing is given for calculating and plotting flaw detection statistics.

Roth, D. J.↗

Removing Silicon Monoxide From Nickel Mirrors

Combination of polishing tool and polishing mixture used to remove adherent fragments of silicon monoxide protective coatings from nickel/aluminum mirrors without altering shapes or harming polishes of mirror surfaces. Polishing technique developed to prepare stained mirrors for recoating to restore high reflectance.

Zaniewski, John J.↗

An Auger electron spectroscopy study of surface-preparation contaminants

There are many cleaning techniques that are presently being employed for surface preparation of materials that are subsequently exposed to ultrahigh vacuum (UHV). Unfortunately, there are virtually no comparative measurements which establish the residual contaminant level of each method. In this report, eleven different cleaning methods, ranging from only detergent cleaning to electrochemical polishing, were applied to identical samples of 347 stainless steel. Two surface conditions, a standard machined surface and a mechanically polished surface, were studied. Auger electron spectroscopy (AES) within a UHV environment was then used to detect the types of contaminants and the magnitudes found on the sample surfaces. It was found that the electrochemical polishing gave the least contaminated surface of all metals studied and that mechanically polished surfaces were significantly cleaner than the as-machined surfaces for any given cleaning method. Furthermore, it was also found that the residual contaminations left by methanol, ethanol, isopropyl alcohol, acetone, and freon finishing rinses are almost the same.

Wu, D.↗

Synchrotron/crystal sample preparation

The Center for Applied Optics (CAO) of the University of Alabama in Huntsville (UAH) prepared this final report entitled 'Synchrotron/Crystal Sample Preparation' in completion of contract NAS8-38609, Delivery Order No. 53. Hughes Danbury Optical Systems (HDOS) is manufacturing the Advanced X-ray Astrophysics Facility (AXAF) mirrors. These thin-walled, grazing incidence, Wolter Type-1 mirrors, varying in diameter from 1.2 to 0.68 meters, must be ground and polished using state-of-the-art techniques in order to prevent undue stress due to damage or the presence of crystals and inclusions. The effect of crystals on the polishing and grinding process must also be understood. This involves coating special samples of Zerodur and measuring the reflectivity of the coatings in a synchrotron system. In order to gain the understanding needed on the effect of the Zerodur crystals by the grinding and polishing process, UAH prepared glass samples by cutting, grinding, etching, and polishing as required to meet specifications for witness bars for synchrotron measurements and for investigations of crystals embedded in Zerodur. UAH then characterized these samples for subsurface damage and surface roughness and figure.

Johnson, R. Barry↗

Neutral ion sources in precision manufacturing

Ion figuring of optical components is a relatively new technology that can alleviate some of the problems associated with traditional contact polishing. Because the technique is non contacting, edge distortions and rib structure print through do not occur. This initial investigation was aimed at determining the effect of ion figuring on surface roughness of previously polished or ductile ground ceramic optical samples. This is the first step in research directed toward the combination of a pre-finishing process (ductile grinding or polishing) with ion figuring to produce finished ceramic mirrors. The second phase of the project is focusing on the development of mathematical algorithms that will deconvolve the ion beam profile from the surface figure errors so that these errors can be successfully removed from the optical components. In the initial phase of the project, multiple, chemical vapor deposited silicon carbide (CVD SiC) samples were polished or ductile ground to specular or near-specular roughness. These samples were then characterized to determine topographic surface information. The surface evaluation consisted of stylus profilometry, interferometry, and optical and scanning electron microscopy. The surfaces, were ion machined to depths from 0-5 microns. The finished surfaces were characterized to evaluate the effects of the ion machining process with respect to the previous processing methods and the pre-existing subsurface damage. The development of the control algorithms for figuring optical components has been completed. These algorithms have been validated with simulations and future experiments have been planned to verify the methods. This paper will present the results of the initial surface finish experiments and the control algorithms simulations.

Fawcett, Steven C.↗

Lifetime Predictions of a Titanium Silicate Glass with Machined Flaws

A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.

Tucker, Dennis S.↗

The Effect of Hole Quality on the Fatigue Life of 2024-T3 Aluminum Alloy Sheet

This paper presents the results of a study whose main objective was to determine which type of fabrication process would least affect the fatigue life of an open-hole structural detail. Since the open-hole detail is often the fundamental building block for determining the stress concentration of built-up structural parts, it is important to understand any factor that can affect the fatigue life of an open hole. A test program of constant-amplitude fatigue tests was conducted on five different sets of test specimens each made using a different hole fabrication process. Three of the sets used different mechanical drilling procedures while a fourth and fifth set were mechanically drilled and then chemically polished. Two sets of specimens were also tested under spectrum loading to aid in understanding the effects of residual compressive stresses on fatigue life. Three conclusions were made from this study. One, the residual compressive stresses caused by the hole-drilling process increased the fatigue life by two to three times over specimens that were chemically polished after the holes were drilled. Second, the chemical polishing process does not appear to adversely affect the fatigue life. Third, the chemical polishing process will produce a stress-state adjacent to the hole that has insignificant machining residual stresses.

Everett, Richard A., Jr.↗

Engineering Design Unit Primary Mirror Segment

The James Webb Space Telescope Primary Mirror Engineering Design Unit (EDU) recently demonstrated the final manufacturing process at L-3-SSG/Tinsley in Richmond, California. Shown in the picture below, the EDU is a prototype 1.4 meter diameter Beryllium mirror that is identical to the 18 flight mirror segments and is used to check out all mirror manufacturing processes prior to the actual flight mirror processing. This recent result gives confidence that all manufacturing processes are in place to figure the 18 flight mirrors. Lessons learned from the EDU have been applied to the flight mirrors improving the performance and processing time and all 18 flight mirrors are well along in their processing at L3-SSG/Tinsley. As a result of completing the final manufacturing demonstration, the EDU mirror was sent to Ball Aerospace in Boulder, Colorado where it is now undergoing integration with the hexapod mount assembly and optical testing checkout. After integration to mount assemblies, flight mirrors will be sent for cryogenic (50 degrees Kelvin) optical testing where the cryogenic distortions will be measured. After cryogenic testing, mirrors will eventually be returned to Tinsley for final cryogenic polishing. During final cryogenic polishing, the inverse of the measured cryogenic distortions will be polished into the mirror to assure the mirror works at it's cryogenic operating temperature. Once cryogenic polishing is completed to final specifications, the mirror will be coated and sent for final cryogenic testing.

Alongi, Chris↗