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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Design Considerations of Polishing Lap for Computer-Controlled Cylindrical Polishing Process

The future X-ray observatory missions, such as International X-ray Observatory, require grazing incidence replicated optics of extremely large collecting area (3 m2) in combination with angular resolution of less than 5 arcsec half-power diameter. The resolution of a mirror shell depends ultimately on the quality of the cylindrical mandrels from which they are being replicated. Mid-spatial-frequency axial figure error is a dominant contributor in the error budget of the mandrel. This paper presents our efforts to develop a deterministic cylindrical polishing process in order to keep the mid-spatial-frequency axial figure errors to a minimum. Simulation studies have been performed to optimize the operational parameters as well as the polishing lap configuration. Furthermore, depending upon the surface error profile, a model for localized polishing based on dwell time approach is developed. Using the inputs from the mathematical model, a mandrel, having conical approximated Wolter-1 geometry, has been polished on a newly developed computer-controlled cylindrical polishing machine. We report our first experimental results and discuss plans for further improvements in the polishing process.

Khan, Gufran S.↗
NASA NTRS2009

Design Considerations of Polishing Lap for Computer-Controlled Cylindrical Polishing Process

This paper establishes a relationship between the polishing process parameters and the generation of mid spatial-frequency error. The consideration of the polishing lap design to optimize the process in order to keep residual errors to a minimum and optimization of the process (speeds, stroke, etc.) and to keep the residual mid spatial-frequency error to a minimum, is also presented.

Khan, Gufran S.↗
NASA NTRS2010

Computer-Controlled Cylindrical Polishing Process for Development of Grazing Incidence Optics for Hard X-Ray Region

The presentation includes grazing incidence X-ray optics, motivation and challenges, mid spatial frequency generation in cylindrical polishing, design considerations for polishing lap, simulation studies and experimental results, future scope, and summary. Topics include current status of replication optics technology, cylindrical polishing process using large size polishing lap, non-conformance of polishin lap to the optics, development of software and polishing machine, deterministic prediction of polishing, polishing experiment under optimum conditions, and polishing experiment based on known error profile. Future plans include determination of non-uniformity in the polishing lap compliance, development of a polishing sequence based on a known error profile of the specimen, software for generating a mandrel polishing sequence, design an development of a flexible polishing lap, and computer controlled localized polishing process.

Khan, Gufran Sayeed↗
NASA NTRS2010

Computer-Controlled Cylindrical Polishing Process for Large X-Ray Mirror Mandrels

We are developing high-energy grazing incidence shell optics for hard-x-ray telescopes. The resolution of a mirror shells depends on the quality of cylindrical mandrel from which they are being replicated. Mid-spatial-frequency axial figure error is a dominant contributor in the error budget of the mandrel. This paper presents our efforts to develop a deterministic cylindrical polishing process in order to keep the mid-spatial-frequency axial figure errors to a minimum. Simulation software is developed to model the residual surface figure errors of a mandrel due to the polishing process parameters and the tools used, as well as to compute the optical performance of the optics. The study carried out using the developed software was focused on establishing a relationship between the polishing process parameters and the mid-spatial-frequency error generation. The process parameters modeled are the speeds of the lap and the mandrel, the tool s influence function, the contour path (dwell) of the tools, their shape and the distribution of the tools on the polishing lap. Using the inputs from the mathematical model, a mandrel having conical approximated Wolter-1 geometry, has been polished on a newly developed computer-controlled cylindrical polishing machine. The preliminary results of a series of polishing experiments demonstrate a qualitative agreement with the developed model. We report our first experimental results and discuss plans for further improvements in the polishing process. The ability to simulate the polishing process is critical to optimize the polishing process, improve the mandrel quality and significantly reduce the cost of mandrel production

Khan, Gufran S.↗
NASA NTRS2011

Graphite Composite Panel Polishing Fixture

The use of high-strength, lightweight composites for the fixture is the novel feature of this innovation. The main advantage is the light weight and high stiffness-to-mass ratio relative to aluminum. Meter-class optics require support during the grinding/polishing process with large tools. The use of aluminum as a polishing fixture is standard, with pitch providing a compliant layer to allow support without deformation. Unfortunately, with meter-scale optics, a meter-scale fixture weighs over 120 lb (.55 kg) and may distort the optics being fabricated by loading the mirror and/or tool used in fabrication. The use of composite structures that are lightweight yet stiff allows standard techniques to be used while providing for a decrease in fixture weight by almost 70 percent. Mounts classically used to support large mirrors during fabrication are especially heavy and difficult to handle. The mount must be especially stiff to avoid deformation during the optical fabrication process, where a very large and heavy lap often can distort the mount and optic being fabricated. If the optic is placed on top of the lapping tool, the weight of the optic and the fixture can distort the lap. Fixtures to support the mirror during fabrication are often very large plates of aluminum, often 2 in. (.5 cm) or more in thickness and weight upwards of 150 lb (68 kg). With the addition of a backing material such as pitch and the mirror itself, the assembly can often weigh over 250 lb (.113 kg) for a meter-class optic. This innovation is the use of a lightweight graphite panel with an aluminum honeycomb core for use as the polishing fixture. These materials have been used in the aerospace industry as structural members due to their light weight and high stiffness. The grinding polishing fixture consists of the graphite composite panel, fittings, and fixtures to allow interface to the polishing machine, and introduction of pitch buttons to support the optic under fabrication. In its operation, the grinding polishing fixture acts as a reaction structure to the polishing tool. It must be stiff enough to avoid imparting a distorted shape to the optic under fabrication and light enough to avoid self-deflection. The fixture must also withstand significant tangential loads from the polishing machine during operations.

Hagopian, John↗
NASA NTRS2011

Experimental Evaluation of Optically Polished Aluminum Panels on the Deep Space Network's 34 Meter Antenna

The potential development of large aperture ground?based "photon bucket" optical receivers for deep space communications has received considerable attention recently. One approach currently under investigation is to polish the aluminum reflector panels of 34?meter microwave antennas to high reflectance, and accept the relatively large spotsize generated by state of?the?art polished aluminum panels. Theoretical analyses of receiving antenna pointing, temporal synchronization and data detection have been addressed in previous papers. Here we describe the experimental effort currently underway at the Deep Space Network (DSN) Goldstone Communications Complex in California, to test and verify these concepts in a realistic operational environment. Two polished aluminum panels (a standard DSN panel polished to high reflectance, and a custom designed aluminum panel with much better surface quality) have been mounted on the 34 meter research antenna at Deep?Space Station 13 (DSS?13), and a remotely controlled CCD camera with a large CCD sensor in a weather?proof container has been installed next to the subreflector, pointed directly at the custom polished panel. The point?spread function (PSF) generated by the Vertex polished panel has been determined to be smaller than the sensor of the CCD camera, hence a detailed picture of the PSF can be obtained every few seconds, and the sensor array data processed to determine the center of the intensity distribution. In addition to estimating the center coordinates, expected communications performance can also been evaluated with the recorded data. The results of preliminary pointing experiments with the Vertex polished panel receiver using the planet Jupiter to simulate the PSF generated by a deep?space optical transmitter are presented and discussed in this paper.

optical receiver↗
NASA NTRS1974

Influence of ultrasounds on electrolytic polishing

On the basis of study of the electrolytic polishing of metal pieces, the following conclusions can be drawn: (1) Utilization of ultrasonically irradiated electrolytes in the electrolytic polishing of copper and steel pieces leads to enhanced polishing quality. (2) Polishing time for the reference pieces was twice as long as for the test pieces. (3) The chemical attack exerted on the surface of the test pieces in order to get the structure of the respective metal lasted less than half as long and yielded superior qualitative results in the copper as well as in the OT 60-2 steel test pieces polished with ultrasonically irradiated electrolytes. (4) The utilization of higher polishing current densities can be explained by the fact that the cavitational effect that arises in the electrolyte owing to ultrasounds contributes to an increase in the solution's electrical conductivity and elimination of gases from the electrolyte.

Gavrila, I.↗
NASA NTRS2003

Fiber Optic Connector Polishing Fixture Assembly

A fiber optic connector polishing fixture assembly for sup- porting a terminus of a fiber optic cable before a polishing surface. The assembly comprises: a fiber optic polishing fixture adapted to support the terminus before the polishing surface; a fixture support connected to the fixture for sup- porting the fixture before the polishing surface; and an adjustable connection between the fixture and the fixture support having user accessible adjustment controls for allowing a user to operate the controls to shift the fixture and fixture support relative to one another for substantially eliminating an apex offset of the terminus with respect to the polishing surface.

John R Kolasinski↗
DOE OSTI2025

First elliptical cavity fabricated with metallographic polishing

The development of an easy and inexpensive Nb sheet preparation process, based on metallographic polishing, has been presented earlier [1, 2]. The aim is to remove the damage layer caused by the rolling process on the sheet in order to reduce the length of surface treatment on completed cavities. The process has been applied on a QPR sample and tested in RF, without any surface chemistry. Its surface resistance is about 4 times lower than the EP baseline at 414 MHz, 2 K [3]. The first elliptical cavity based on this principle has been produced at KEK, starting with large polished sheets developed in collaboration between IJCLAB, and the company LAMPLAN. We present its 1st RF test at KEK, with a HF rinsing and a recrystallization treatment at 600C for 10h, without any chemical etching at first. References: *1: C. Antoine and R. Crooks, “Reducing Electropolishing Time with Chemical-Mechanical Polishing”, SRF2009. *2: O. Hryhorenko, et al., "An innovative approach of surface polishing for SRF cavity applications". Journal of Manufacturing and Materials Processing, 2023. 7(2): p. 62. *3: O. Hryhorenko, et al., "Recent advances in metallographic polishing for SRF application", SRF2023.

Dohmae, Takeshi [High Energy Accelerator Research ↗
NASA NTRS1981

Simultaneous ion sputter polishing and deposition

Results of experiments to study ion beam sputter polishing in conjunction with simultaneous deposition as a mean of polishing copper surfaces are presented. Two types of simultaneous ion sputter polishing and deposition were used in these experiments. The first type utilized sputter polishing simultaneous with vapor deposition, and the second type utilized sputter polishing simultaneous with sputter deposition. The etch and deposition rates of both techniques were studied, as well as the surface morphology and surface roughness.

Rutledge, S.↗
NASA NTRS1982

Strength advantages of chemically polished boron fibers before and after reaction with aluminum

In order to determine their strength potential, the fracture properties of different types of commercial boron fibers were measured before and after application of secondary strengthening treatments. The principal treatments employed were a slight chemical polish, which removed low strength surface flaws, and a heat treatment in oxygen, which contracted the fibers and thereby compressed intrinsic bulk flaws. Those fiber types most significantly strengthened were 200 to 400 micrometers (8 to 16 mil) diameter boron on tungsten fibers produced in a single chemical vapor deposition reactor. The slight polish increased average tensile strenghts from 3.4 to 4.4 CN/m2 (500 to 640 ksi) and reduced coefficients of variation from about 15 to 3 percent. The oxygen heat treatment plus slight polish further improved average strengths to 5.5 GN/m2 (800 ksi) with coefficients near 3 percent. To ascertain whether these excellent properties could be retained after fabrication of B/Al composites, as produced and polished 203 micrometers (8 mil) fibers were thinly coated with aluminum, heat treated at B/Al fabrication temperatures, and then tested in tension and flexure at room temperature. The pre-polished fibers were observed to retain their superior strengths to higher temperatures than the as-produced fibers even though both were subjected to the same detrimental reaction with aluminum.

Dicarlo, J. A.↗
NASA NTRS2009

Development of a Computer-Controlled Polishing Process for X-Ray Optics

The future X-ray observatory missions require grazing-incidence x-ray optics with angular resolution of < 5 arcsec half-power diameter. The achievable resolution depends ultimately on the quality of polished mandrels from which the shells are replicated. With an aim to fabricate better shells, and reduce the cost/time of mandrel production, a computer-controlled polishing machine is developed for deterministic and localized polishing of mandrels. Cylindrical polishing software is also developed that predicts the surface residual errors under a given set of operating parameters and lap configuration. Design considerations of the polishing lap are discussed and the effects of nonconformance of the lap and the mandrel are presented.

Khan, Gufran S.↗
NASA NTRS2012

Experimental Evaluation of the "Polished Panel Optical Receiver" Concept on the Deep Space Network's 34 Meter Antenna

The potential development of large aperture ground-based "photon bucket" optical receivers for deep space communications has received considerable attention recently. One approach currently under investigation proposes to polish the aluminum reflector panels of 34-meter microwave antennas to high reflectance, and accept the relatively large spotsize generated by even state-of-the-art polished aluminum panels. Here we describe the experimental effort currently underway at the Deep Space Network (DSN) Goldstone Communications Complex in California, to test and verify these concepts in a realistic operational environment. A custom designed aluminum panel has been mounted on the 34 meter research antenna at Deep-Space Station 13 (DSS-13), and a remotely controlled CCD camera with a large CCD sensor in a weather-proof container has been installed next to the subreflector, pointed directly at the custom polished panel. Using the planet Jupiter as the optical point-source, the point-spread function (PSF) generated by the polished panel has been characterized, the array data processed to determine the center of the intensity distribution, and expected communications performance of the proposed polished panel optical receiver has been evaluated.

photon counting detection↗
NASA NTRS2019

Deterministic Polishing of Replicating Grazing-Incidence Mandrels

In an effort to manufacture high-angular-resolution, grazing-incidence, x-ray optics, Marshall Space Flight Center (MSFC) is taking measures to improve its electroformed replicated optics. A key development is the use of computer-numerical control (CNC) polishing to deterministically improve the surface of electroless nickel mandrels used to replicate grazing- incidence optics. Metrology, control software and polishing parameters must function together seamlessly to reach the specifications required to replicate sub-arcsecond optics. Each change in polishing parameters effects the wear pattern of the polishing head. Using Richardson-Lucy deconvolution, the controller software fits the wear pattern to metrology data to calculate the changing feedrates across the mandrel. Here we present an overview of our process, and early results showing the effectiveness of deterministic polishing for replicated optics.

Davis, Jacqueline↗
NASA NTRS2013

Tracking Performance of Upgraded "Polished Panel" Optical Receiver on NASA's 34 Meter Research Antenna

There has been considerable interest in developing and demonstrating a hybrid "polished panel" optical receiver concept that would replace the microwave panels on the Deep Space Network's (DSN) 34 meter antennas with highly polished aluminum panels, thus enabling simultaneous opticaland microwave reception. A test setup has been installed on the 34 meter research antenna at DSS-13 (Deep Space Station 13) at NASA's Goldstone Deep Space Communications Complex in California in order to assess the feasibility of this concept. Here we describe the results of a recent effort todramatically reduce the dimensions of the point-spread function (PSF) generated by a custom polished panel, thus enabling improved optical communications performance. The latest results are compared to the previous configuration in terms of quantifiable PSF improvement. In addition, the performance of acquisition and tracking algorithms designed specifically for the polished panel PSF are evaluated and compared, based on data obtained from real-time tracking of planets and bright stars with the 34 meter research antenna at DSS-13.

optima↗
DOE OSTI2025

A New Method for Polishing Laminated Dissimilar Metals

Here, this paper presents a novel method for preparing metallographic samples of laminated dissimilar metals, specifically a layered structure of zirconium (Zr), vanadium (V), and tungsten (W), which pose a challenge due to their differing crystal structures and hardness levels. The work was motivated by the need to develop a cladding for tungsten targets in spallation neutron sources, where a zirconium face is applied over an interlayer of either vanadium or titanium to prevent the formation of brittle intermetallic compounds such as ZrW 2 . Traditional polishing techniques prove inadequate because each constituent metal requires a different polishing approach based on its unique material properties. The methodology outlined includes a sequential process involving conductive epoxy mounting, successive grinding and polishing with specific abrasives, and a final chemical-mechanical polish using a colloidal silica-based solution. Optical microscopy confirmed that this multi-step process successfully produced scratch-free surfaces and minimized surface relief across the different metal interfaces. Although developed for refractory metals, this approach shows promise for other layered structures comprised of transition metals, offering a meticulous yet effective technique for high-quality metallographic sample preparation.

Newberry, Daniel [Oak Ridge National Laboratory (O↗
DOE OSTI2025

Does one need to polish electrodes in an eight pattern? Automation provides the answer

Automation of electrochemical measurements can accelerate the discovery of new electroactive materials. One of the hurdles to automated electrochemical measurement is the pretreatment of electrodes because mechanical polishing is usually conducted manually. Here we investigate the automation of electrochemical measurements using a robotic arm. We demonstrate automated mechanical polishing using a station with a moving polishing pad and evaluate the effect of different polishing patterns. Our automatic method improved the corroded electrodes, and we found the effect of pattern was not significant, which diverges from the current common belief amongst practitioners that a figure eight pattern is best for pretreatment. This research is a step toward automating electrochemistry experiments without human intervention.

Yoshikawa, Naruki [University of Toronto, ON (Cana↗