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Mirror refurbishment processing is described, and the results of processing 251 mirror assemblies are reported. The mirror replica bonding, optical tests, electrical discharge machining, and vacuum coating are discussed.
The X-ray performance of the Advanced X-ray Astrophysics Facility TMA in the 0.277-6.4-keV range. The precise figure and smooth surface originally specified (which were expected from the in-process optical and mechanical measurements) are verified. The paper primarily describes the test equipment and methods used and gives examples of the detailed on-axis and off-axis data.
A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.
This presentation summarizes the case for using precision assembly of space structures for efficient and cost-effective construction of large systems such as iSAT primary mirror assembly and surface applications
A scan mirror assembly which is part of a thematic mapper system is described with emphasis on mechanical aspects of the design. Features of the oscillating scan mirror mechanism include: a low level of structural vibration for the impact energies involved in mirror oscillation and return of energy lost during impact to the mirror by applying torque during the instant of impact.
A revolutionary way to produce a mirror and mirror assembly is to cast the entire part at once from a metal alloy that combines all of the desired features into the final part: optical smoothness, curvature, flexures, tabs, isogrids, low CTE, and toughness. In this work, it has been demonstrated that castable mirrors are possible using bulk metallic glasses (BMGs, also called amorphous metals) and BMG matrix composites (BMGMCs). These novel alloys have all of the desired mechanical and thermal properties to fabricate an entire mirror assembly without machining, bonding, brazing, welding, or epoxy. BMGs are multi-component metal alloys that have been cooled in such a manner as to avoid crystallization leading to an amorphous (non-crystalline) microstructure. This lack of crystal structure and the fact that these alloys are glasses, leads to a wide assortment of mechanical and thermal properties that are unlike those observed in crystalline metals. Among these are high yield strength, carbide-like hardness, low melting temperatures (making them castable like aluminum), a thermoplastic processing region (for improving smoothness), low stiffness, high strength-to-weight ratios, relatively low CTE, density similar to titanium alloys, high elasticity and ultra-smooth cast parts (as low as 0.2-nm surface roughness has been demonstrated in cast BMGs). BMGMCs are composite alloys that consist of a BMG matrix with crystalline dendrites embedded throughout. BMGMCs are used to overcome the typically brittle failure observed in monolithic BMGs by adding a soft phase that arrests the formation of cracks in the BMG matrix. In some cases, BMGMCs offer superior castability, toughness, and fatigue resistance, if not as good a surface finish as BMGs. This work has demonstrated that BMGs and BMGMCs can be cast into prototype mirrors and mirror assemblies without difficulty.
The AXAF-1 High Resolution Mirror Assembly (HRMA) consists of four nested mirror pairs of Wolter Type-1 grazing incidence optics. The HRMA assembly and alignment will take place in a vibration-isolated, cleanliness class 100, 18 meter high tower at an Eastman Kodak Company facility in Rochester, NY. Each mirror pair must be aligned such that its image is coma-free, and the four pairs must be aligned such that their images are coincident. In addition, both the HRMA optical axis and focal point must be precisely known with respect to physical references on the HRMA. The alignment of the HRMA mirrors is measured by the HRMA Alignment Test System (HATS), which is an integral part of the tower facility. The HATS is configured as a double-pass, autocollimating Hartmann test where each mirror aperture is scanned to determine the state of alignment. This paper will describe the design and operation of the HATS.
A 40 cm diameter mirror assembly was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5 m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two face sheets. The 93% lightweighted Corning ULE mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.
The manufacture and testing of the Technology Mirror Assembly (TMA), a prototype Wolter I telescope scaled to the dimensions of the innermost element of the High-Resolution Mirror Assembly for the NASA Advanced X-ray Astrophysics Facility (AXAF), are reviewed. Consideration is given to the grinding, polishing, coating, and assembly of the zerodur TMA blanks, the TMA mount design, and the test procedures used at the MSFC X-ray Calibration Facility. Test results indicate FWHM resolution less than 0.5 arcsec, but with significant near-field scattering attributed to ripple; further long-lap polishing is suggested.
The fabrication of the Technology Mirror Assembly (TMA) is complete, and performance predictions were made based upon mechanical and visible light measurements of the surface properties. An X-ray calibration program has been executed, and a preliminary analysis of a portion of the data is presented. The X-ray image distribution results are in reasonable agreement with the performance predictions which were calculated prior the start of the X-ray tests. The measured X-ray imaging performance approaches that expected for the Advanced X-ray Astrophysics Facility (AXAF).
The authors describe the design of a liquid helium temperature prototype secondary mirror assembly (PSMA) under developement for the NASA Space Infrared Telescope Facility (SIRTF) program. The SIRTF secondary mirror assembly must operate below 4 K and provide highly precise two-axis dynamic tilting (chopping) in addition to the conventional functions needed by the SIRTF observatory. The PSMA design uses a fused quartz mirror kinematically attached at its center to an aluminum cruciform. The mirror/cruciform assembly is driven in tilt about its combined center of mass using a unique flexure pivot and a four-actuator control system with feedback provided by pairs of differential position sensors. The voice coil actuators are mounted on a second flexture-pivoted mass, enhancing servo system stability and isolating the telescope from vibration-induced disturbances. The mirror/cruciform and the reaction mass are attached to opposite sides of an aluminum mounting plate whose dimensional characteristics are nominally identical to those of the aluminum flexure pivot material. The mounting plate is connected to the outer housing by a six-degree-of-freedom focus and centering mechanism using pivoted actuation levers driven by lead screw/harmonic drive/stepper motor assemblies.
A 43cm diameter stacked core mirror demonstrator was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two CNC pocket milled face sheets. The 93% lightweighted Corning ULE® mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.
Lightweight and high resolution optics are needed for future space-based x-ray telescopes to achieve advances in high-energy astrophysics. Past missions such as Chandra and XMM-Newton have achieved excellent angular resolution using a full shell mirror approach. Other missions such as Suzaku and NuSTAR have achieved lightweight mirrors using a segmented approach. This paper describes a new approach, called meta-shells, which combines the fabrication advantages of segmented optics with the alignment advantages of full shell optics. Meta-shells are built by layering overlapping mirror segments onto a central structural shell. The resulting optic has the stiffness and rotational symmetry of a full shell, but with an order of magnitude greater collecting area. Several meta-shells so constructed can be integrated into a large x-ray mirror assembly by proven methods used for Chandra and XMM-Newton. The mirror segments are mounted to the meta-shell using a novel four point semi-kinematic mount. The four point mount deterministically locates the segment in its most performance sensitive degrees of freedom. Extensive analysis has been performed to demonstrate the feasibility of the four point mount and meta-shell approach. A mathematical model of a meta-shell constructed with mirror segments bonded at four points and subject to launch loads has been developed to determine the optimal design parameters, namely bond size, mirror segment span, and number of layers per meta-shell. The parameters of an example 1.3 m diameter mirror assembly are given including the predicted effective area. To verify the mathematical model and support opto-mechanical analysis, a detailed finite element model of a meta-shell was created. Finite element analysis predicts low gravity distortion and low sensitivity to thermal gradients.
A Scan Mirror Assembly (SMA) was created to rotate its SiC mirror through 8.5 deg. in 90 seconds, then to return in 2 seconds, and repeating this motion continuously for at least three years. Unique design features are: lightly preloaded, large angular-contact bearings; bearing preload using a convoluted diaphragm; launch locks avoided by static balancing; limited-scan rotation so ball travel does not overlap; and silicon carbide mirror on semi-kinematic mounts.
Goal: Consider design challenges for X-Ray Surveyor beyond mirror segment fabrication and mounting. Unique challenges for modular Mirror Assembly.
Data from the thematic mapper scan mirror assembly (SMA) acceptance test are presented. Documentation includes: (1) a list of the acceptance test discrepancies; (2) flight 1 SMA test data book; (3) flight 1 SMA environmental report; (4) the configuration verification index; (5) the flight 1 SMA test failure reports; (6) the flight 1 data tapes log; and (7) the requests for deviation/waivers.
Prior to launch, the High Resolution Mirror Assembly (HRMA) of the Chandra X-ray Observatory underwent extensive ground testing at the X-ray Calibration Facility (XRCF) at the Marshall Space Flight Center in Huntsville. Observations made during the post-launch Orbital Activation and Calibration period, allow the on-orbit condition of the X-ray optics to be assessed. Based on these ground-based and on-orbit data, we examine the alignment of the x-ray optics based on the PSF, and the boresight and alignment of the optical axis alignment relative to the detectors. We examine the vignetting and the single reflection ghost suppression properties of the telescope. Slight imperfections in alignment lead to a small azimuthal dependence of the off-axis area; the morphology of off-axis images also shows an additional small azimuthal dependence varying as 1/2 the off-axis azimuth angle.
This paper analyzes a recently published model for Lynx Mirror Assembly production duration, to understand the sensitivity of duration to various factors. The factors considered are finite process yield, knowledge of the individual process times and finite server reliability. In all of these cases, closed form estimates are given along with numerical examples. This initial analysis indicates that accurate and precise knowledge of the process times is fundamental to making an accurate prediction of schedule duration. Analysis of the failure of any given server is also explained and can be used as the basis of a rational sparing policy.