SEARCH · Search NASA

Results for “Electroforming”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9

All sources NASA NTRS DOE OSTI

NASA NTRS1994

Replicate Wolter-I x-ray mirrors

Cylindrical (hyperbolic - parabolic Wolter I) mirrors have been electroformed from nickel over an electroless nickel-phosphorous (NiP) plated aluminum mandrel in support of the NASA AXAF-S x-ray spectrometer program. The electroless nickel was diamond turned and polished to achieve a surface finish of 10 angstroms rms or better. Gold was then plated on the nickel alloy after an electrochemical passivation step. Next a heavy layer of pure nickel was plated one millimeter thick with controlled stress at zero using a commercial PID program to form the actual mirror. This shell was removed from the NiP alloy coated mandrel by cryogenic cooling and contraction of the aluminum to release the mirror. It is required that the gold not adhere well to the NiP but all other plated coatings must exhibit good adherence. Four mirrors were fabricated from two mandrels prepared by this method. The area of each part is 0.7 square meters (7.5 square feet).

Engelhaupt, D. E.↗

NASA NTRS1994

SSME Main Combustion Chamber (MCC) 'Hot Oil' Dewaxing

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax(registered mark) casting compound. Rigidax(registered mark) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

Akpati, Anthony U.↗

NASA NTRS1995

Advancing MEMS Technology Usage through the MUMPS (Multi-User MEMS Processes) Program

In order to help provide access to advanced micro-electro-mechanical systems (MEMS) technologies and lower the barriers for both industry and academia, the Microelectronic Center of North Carolina (MCNC) and ARPA have developed a program which provides users with access to both MEMS processes and advanced electronic integration techniques. The four distinct aspects of this program, the multi-user MEMS processes (MUMP's), the consolidated micro-mechanical element library, smart MEMS, and the MEMS technology network are described in this paper. MUMP's is an ARPA-supported program created to provide inexpensive access to MEMS technology in a multi-user environment. It is both a proof-of-concept and educational tool that aids in the development of MEMS in the domestic community. MUMP's technologies currently include a 3-layer poly-silicon surface micromachining process and LIGA (lithography, electroforming, and injection molding) processes that provide reasonable design flexibility within set guidelines. The consolidated micromechanical element library (CaMEL) is a library of active and passive MEMS structures that can be downloaded by the MEMS community via the internet. Smart MEMS is the development of advanced electronics integration techniques for MEMS through the application of flip chip technology. The MEMS technology network (TechNet) is a menu of standard substrates and MEMS fabrication processes that can be purchased and combined to create unique process flows. TechNet provides the MEMS community greater flexibility and enhanced technology accessibility.

Koester, D. A.↗

NASA NTRS1998

Hard X-Ray and Wide Focusing Telescopes

Studies are being carried out to compare the performance of several different separation materials used in the replication process. This report presents the results obtained during the second year of a program which consists of replicating smooth, thin substrates, depositing multilayer coatings upon them, and evaluating their performance. Replication and multilayer coatings are both critically important to the development of focussing hard X-ray telescopes that function up to 100 keV. The activities of the current year include extending the comparison between sputtered amorphous carbon and evaporated gold to include sputtered as well as evaporated gold. The figure of merit being the smoothness of the replica which has a direct effect on the specular reflectivity. These results were obtained with epoxy replication, but they should be applicable to electroformed nickel, the process we expect to use for the ultimate replicated optics.

Gorenstein, Paul↗

NASA NTRS1998

Next Generation Space Telescope Ultra-Lightweight Mirror Program

The Next Generation Space Telescope is currently envisioned as a eight meter diameter cryogenic deployable telescope that will operate at the earth sun libration point L2. A number of different designs are being examined within NASA and under industry studies by Ball Aerospace, Lockheed-Martin and TRW. Although these designs differ in many respects, they all require significant advancements in the state-of-the-art with respect to large diameter, ultra-lightweight, mirrors. The purpose of this paper is to provide insight into the current status of the mirror development program NGST is a tremendously ambitious undertaking that sets the mark for new NASA missions. In order to achieve the weight, cost and performance requirements of NGST, the primary mirror must be made lighter, cheaper and better than anything that has ever been done. In order to accomplish this an aggressive technology program has been put in place. The scope of the program was determined by examining historically what has been accomplished; assessing recent technological advances in fabrication and testing; and evaluating the effect of these advances relative to enabling the manufacture of lightweight mirrors that meet NGST requirements. As it is currently envisioned, the primary mirror for NGST is on the order of eight meters in diameter, it is to be diffraction limited at a wave length of 2 microns and has an overall weight requirement of 15 kilograms per square meter. Two large scale demonstration projects are under way along with a number of smaller scale demonstrations on a variety of mirror materials and concepts. The University of Arizona (UA) mirror concept is based around a 2mm thick Borosilicate glass face sheet mounted to a composite backplane structure via actuators for mirror figure correction. The Composite Optics Inc.(COI) concept consists of a 3.2mm thick Zerodur face sheet bonded to a composite support structure which in turn is mounted to a composite backplane structure via actuators for mirror phasing. These mirrors are due to be performance tested in ambient conditions in the fall of '98, and cryogenically tested in the spring of '99. The smaller scale efforts include the following: Beryllium is being investigated at Ball Aerospace, Electroform nickel is being investigated in-house at MSFC, Chemical Vapor Deposition (CVD) Silicon Carbide (SiC) is being investigated at Morton International Silicon mirrors are being investigated at Schafer, Carbon Fiber Reinforced Silicon Carbide (CSIC) is being investigated at IABG. SiC at SSG, Composite mirrors at COI, pyrolyzed graphite mirrors at Ultramet, reaction bonded SiC mirrors at Xinetics, along with techniques for lightweighting using waterjets at Waterjet Technology Inc. are all being investigated under the Small Business innovative Research Program SBIR program. A procurement for a third large scale demonstration (nominally 1.5m in diameter) is being planned for release this fall.

Bilbro, James W.↗

NASA NTRS1999

Constellation-X Spectroscopy X-Ray Telescope Requirements and Development Program: MSFC Research Program

The Constellation-X Spectroscopy X-ray Telescope (SXT) will provide high-throughput, high-resolution spectroscopy of cosmic sources, from 0.25 keV to 10 keV. Key to this capability is the development of large (1.6 m diameter), lightweight optics for the SXT mirror assembly. Teams led by NASA's Marshall Space Flight Center (MSFC), by NASA's Goddard Space Flight Center (GSFC), and by Italy's Osservatorio Astronomico di Brera (OAB) are currently developing competing mirror technologies for this planned mission. Each team is making significant research progress in developing mirror technologies which satisfy the SXT requirements for lightweight optics, consistent with a system-level optical performance of better than 15 arcsec half-power diameter. The NASA Marshall Space Flight Center (MSFC), in collaboration with the Smithsonian Astrophysical Observatory (SAO), has focussed its efforts on full-shell replicated optics, of electroformed nickel alloys. Recent progress in identifying a surface treatment to effect low, controlled adhesion and, more significantly, in developing new high-strength nickel alloys make this a viable, low cost approach to satisfying the SXT requirements.

O'Dell, S. L.↗

NASA NTRS1999

Development of Constellation-X Optics Technologies at MSFC

One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high-strength electroformed nickel alloys. In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.

Odell, S. L.↗

NASA NTRS2000

The Fabrication of Replicated Optics for Hard X-Ray Astronomy

We describe the fabrication process for producing shallow-graze-angle mirrors for hard x-ray astronomy. This presentation includes the generation of the necessary super-polished mandrels, their metrology, and the subsequent mirror shell electroforming and testing.

Speegle, C. O.↗

NASA NTRS2000

Development of Constellation-X Optics Technologies at MSFC

One of the major technological challenges for the Constellation X-ray Mission is the development of light-weight, high-resolution, grazing-incidence optics. NASA's Marshall Space Flight Center is developing and evaluating candidate technologies, based upon full-shell replication off precision mandrels. Here we report on recent progress in meeting the weight and imaging-performance requirements, using very thin, high- strength electroformed nickel alloys, In addition, we briefly describe MSFC's optics fabrication, metrology, and x-ray test facilities.

Ramsey, B. D.↗

NASA NTRS2000

Development of Constellation-X Optics Technologies at MSFC

ODell, S. L.↗

NASA NTRS2000

The Fabrication of Replicated Optics for Hard X-Ray Astronomy

Speegle, C. O.↗

NASA NTRS2000

Metrology Mount and Optics Mandrels

This document is the Final Report for NASA Grant NAG8-1198 from NASA Marshall Space Flight Center (MSFC) to the Smithsonian Astrophysical Observatory (SAO). The Grant is entitled "Metrology Mount and Optics Materials." This final report is required by the terms of the Grant. The period of performance was from September 15, 1995 through January 14, 1999. Total funding received by SAO from MSFC for this effort was, $254,000. Mr. Lester Cohen carried out most of the work at SAO, but received limited support from other engineers, technicians, and designers. Dr. Harvey Tananbaum, the Principal Investigator for the grant provided overall direction and work- assessment. The Grant has had two funding augmentations to its basic amount and has, over time, emphasized three different research areas - each of which has been an extension of earlier research. The research activity was in 2 areas: (1) Expert opto-structural studies related to separation mechanics and effects of electro formed nickel X-ray mirrors. and (2) Design, fabrication and evaluation of a low force metrology and assembly station for light weight full shell electroformed X-ray mirrors.

Tananbaum, H.↗

NASA NTRS2000

Electro-Formed Mirrors for Both X-Ray and Visible Astronomy

The Space Optics Manufacturing Technology Center of NASA's Marshall Space Flight Center is involved in the development of nickel and nickel alloy electroformed mirrors for rapid production of space-based optical systems. The current state of the process is discussed- for both cylindrical x-ray mirrors and normal incidence mirrors for visible and infrared applications.

Ritter, J.↗

NASA NTRS2001

Innovative Method for Developing a Helium Pressurant Tank Suitable for the Upper Stage Flight Experiment

The AFRL USFE project is an experimental test bed for new propulsion technologies. It will utilize ambient temperature fuel and oxidizers (Kerosene and Hydrogen peroxide). The system is pressure fed, not pump fed, and will utilize a helium pressurant tank to drive the system. Mr. DeLay has developed a method for cost effectively producing a unique, large pressurant tank that is not commercially available. The pressure vessel is a layered composite structure with an electroformed metallic permeation barrier. The design/process is scalable and easily adaptable to different configurations with minimal cost in tooling development 1/3 scale tanks have already been fabricated and are scheduled for testing. The full-scale pressure vessel (50" diameter) design will be refined based on the performance of the sub-scale tank. The pressure vessels have been designed to operate at 6,000 psi. a PV/W of 1.92 million is anticipated.

DeLay, Tom K.↗

NASA NTRS2001

Hard X-Ray And Wide Focusing Telescopes

The development of a hard X-ray telescope requires new technology for both substrates and coatings. Our activities in these two areas were carried out virtually in parallel during most of the past few years. They are converging on the production of our first integral conical, substrate electroformed mirror that will be coated with a graded d-spacing multilayer. Its imaging properties and effective area will be measured in hard X-ray beams. We discuss each of these activities separately in the following two sections.

Gorenstein, Paul↗

NASA NTRS2001

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.↗

NASA NTRS2002

Production of Ultra-Light Normal Incidence Mirrors

Mirrors fabrication for large aperture telescopes is an important aspect in space exploration programs. One of the cost effective techniques to obtain such mirrors is electroplating of Ni-Co alloys from sulfamate solution. The Center for Irradiation of Materials at Alabama A&M University - Research Institute has been involved in a NASA-MSFC project for producing ultra-light Ni-Co alloy mirrors since the summer of year 2000. The goal of this project is to obtain ultra-light, high strength electroformed large aperture normal incidence replicated mirrors, (weighting less than 5 kg/m2), free of stress, with a good figure and reproducible thickness variation. In order to simplify the control of parameters such as temperature gradient, concentration gradient, distribution of the electric field lines and flow control, the proposed geometry involves a cylindrical main tank contained in another cylindrical tank, which plays the role of a weir. Designs were created to accommodate the new horizontal position of the mandrel and the pipes fitting through the outer tank's lid. The inner tank contains the working electrodes and a series of sensors for monitoring temperature, flow, stress and pH. The outer tank holds the electric heaters, the filters and a part of the piping system. Another two tanks complete the setup and serve for rinsing/preheating and equilibrating the electroplating bath. This paper will describe advantages of the new experimental setup and the parameters achieved in the electroplating bath for the proposed geometry.

Jones, Ruth↗

NASA NTRS2002

Development of High Resolution Mirrors and Cd-Zn-Te Detectors for Hard X-ray Astronomy

We describe the fabrication and implementation of a high-resolution conical, grazing- incidence, hard X-ray (20-70 keV) telescope. When flown aboard stratospheric balloons, these mirrors are used to image cosmic sources such as supernovae, neutron stars, and quasars. The fabrication process involves generating super-polished mandrels, mirror shell electroforming, and mirror testing. The cylindrical mandrels consist of two conical segments; each segment is approximately 305 mm long. These mandrels are first, precision ground to within approx. 1.0 micron straightness along each conical segment and then lapped and polished to less than 0.5 micron straightness. Each mandrel segment is the super-polished to an average surface roughness of approx. 3.25 angstrom rms. By mirror shell replication, this combination of good figure and low surface roughness has enabled us to achieve 15 arcsec, confirmed by X-ray measurements in the Marshall Space Flight Center 102 meter test facility. To image the focused X-rays requires a focal plane detector with appropriate spatial resolution. For 15 arcsec optics of 6 meter focal length, this resolution must be around 200 microns. In addition, the detector must have a high efficiency, relatively high energy resolution, and low background. We are currently developing Cadmium-Zinc-Telluride fine-pixel detectors for this purpose. The detectors under study consist of a 16x16 pixel array with a pixel pitch of 300 microns and are 1 mm and 2 mm thick. At 60 keV, the measured energy resolution is around 2%.

Ramsey, Brian D.↗