Engineering topics
Publications and source records attributed to Kester, Thomas.
A multi-beam LTP is under development at MSFC in collaboration with Lawrence Berkeley National laboratory and Brookhaven National Laboratory. The Multi-beam LTP has been fully assembled. First tests of the MBLTP has demonstrated the feasibility of the multibeam approach. The calibrations are under way. The MBLTP is intended to be used for metrology support of the deterministic polishing experiments.
The multi-beam long trace profiler (MB-LTP) is under development at NASA's Marshall Space Flight Center. The traditional LTPs scans the surface under the test by a single laser beam directly measuring the surface figure slope errors. While capable of exceptional surface slope accuracy, the LTP single beam scanning has slow measuring speed. Metrology efficiency can be increased by replacing the single laser beam with multiple beams that can scan a section of the test surface at a single instance. The increase in speed with such a system would be almost proportional to the number of laser beams. The progress for a multi-beam long trace profiler development is presented.
The multi-beam long trace profiler (LTP) under development at NASA s Marshall Space Flight Center[1] is designed to increase the efficiency of metrology of replicated X-ray optics. The traditional LTP operates on a single laser beam that scans along the test surface to detect the slope errors. While capable of exceptional surface slope accuracy, the LTP single beam scanning has slow measuring speed. As metrology constitutes a significant fraction of the time spent in optics production, an increase in the efficiency of metrology helps in decreasing the cost of fabrication of the x-ray optics and in improving their quality. Metrology efficiency can be increased by replacing the single laser beam with multiple beams that can scan a section of the test surface at a single instance. The increase in speed with such a system would be almost proportional to the number of laser beams. A collaborative feasibility study has been made and specifications were fixed for a multi-beam long trace profiler. The progress made in the development of this metrology system is presented.
Precision forming mandrels are one element in X-ray mirror development at NASA. Current mandrel fabrication process is capable of meeting the allocated precision requirements for a 5 arcsec telescope. A manufacturing plan is outlined for a large IXO-scale program.
In order to fulfill the angular resolution requirements and make the performance goals for future NASA missions feasible, it is crucial to develop instruments capable of fast and precise figure metrology of x-ray optical elements for further correction of the surface errors. The Long Trace Profilometer (LTP) is an instrument widely used for measuring the surface figure of grazing incidence X-ray mirrors. In the case of replicated optics designed for x-ray astronomy applications, such as mirrors and the corresponding mandrels have a cylindrical shape and their tangential profile is parabolic or hyperbolic. Modern LTPs have sub-microradian accuracy, but the measuring speed is very low, because the profilometer measures surface figure point by point using a single laser beam. The measurement rate can be significantly improved by replacing the single optical beam with multiple beams. The goal of this study is to demonstrate the viability of multi-beam metrology as a way of significantly improving the quality and affordability of replicated x-ray optics. The multi-beam LTP would allow one- and two-dimensional scanning with sub-microradian resolution and a measurement rate of about ten times faster compared to the current LTP. The design details of the instrument's optical layout and the status of optical tests will be presented.
Future x-ray astronomical missions, like the International X-ray Observatory (IXO), will likely require replicated mirrors to reduce both mass and production costs. Accurately figured and measured mandrels - upon which the mirror substrates are thermally formed - are essential to enable these missions. The challenge of making these mandrels within reasonable costs and schedule has led the Goddard and Marshall Space Flight Centers to develop in-house processes and to encourage small businesses to attack parts of the problem. Both Goddard and Marshall have developed full-aperture polishing processes and metrologies that yield high-precision axial traces of the finished mandrels. Outside technologists have been addressing challenges presented by subaperture CNC machining processes: particularly difficult is the challenge of reducing mid-spatial frequency errors below 2 nm rms. The end-product of this approach is a realistic plan for the economically feasible production of mandrels that meet program requirements in both figure and quantity.
We are developing grazing-incidence x-ray optics for astronomy. The optics are full-cylinder mirror shells fabricated using electroformed-nickel replication off super-polished mandrels. For space-based applications where weight is at a premium, very-thin-walled, light-weight mirrors are required. Such shells have been fabricated at MSFC with greater than 15 arcsec resolution. The challenge, however, is to preserve this resolution during mounting and assembly. We present here a status report on a mounting and alignment system currently under development at Marshall Space Flight Center to meet this challenge.
The Constellation-X Spectroscopy X-ray telescope (SXT) is designed to be built from X-ray optic segments. The X-ray segments will be fabricated from the segmented mandrels using a replication process. The purpose of the incoming metrology is to map the surface of the mandrels, so the performance of the X-ray optics produced can be predicted. Three Constellation-X segmented mandrels have been delivered to MSFC for incoming metrology. The segmented mandrels are 30-degree sections of a cylindrical surface and have diameters of 1.0 m, 1.2 m and 1.6 m. The maximum dimensions of the optical surface are 1.0 m axial length and 0.5 m azimuthal segment length. The metrology of the mandrels consists of the measurement of their slope differences, roundness, absolute radius, axial profile and microroughness. Accuracy goals for each type of measurement and the accuracy of the instruments used for the measurements will be discussed. The results of the mandrel metrology together with the performance predictions will be presented.
We are developing grazing incidence x-ray optics for a balloon-borne hard-x-ray telescope (HERO). The HERO mirror shells are fabricated using electroform-nickel replication off super-polished cylindrical mandrels. One of the sources for mirror resolution error is departure of the shell figure from prescription. We have modified a Vertical-scan Long Trace Profilometer (VLTP) in order to measure the figure of the inner surface of the HERO mirror shells for diameters as small as 76 mm. Mirror alignment method and sources for systematic errors will be discussed. Comparison of figure metrology of the mandrel and the shells will be presented together with results from x-ray tests.
The long trace profiler (LTP) is the instrument of a choice for the surface figure measurement of grazing incidence mirrors. The modification of conventional LTP, the vertical-scan LTP, capable of measuring the surface figure of replicated shell mirrors is now in operation at Marshall Space Flight Center. Sources of systematic error for vertical-scan LTP are discussed. Calibration method using a test flat mirror and results of measurements are presented.