Optimizing the electroforming process for full shell X-ray optics
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Engineering topics
Publications and source records attributed to Wayne Baumgartner.
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The X-Ray & Cryogenic Facility (XRCF) at Marshall Space Flight Center is the world’s largest x-ray optic calibration facility and NASA’s premier cryogenic optical test facility. Built specifically to calibrate the Chandra telescope, the facility contributed to several other x-ray missions until 2005 when it became dedicated to normal incidence optical testing at cryogenic temperatures. Recently the facility’s x-ray test capability has been returned to service and updated. New beam monitors, focal plane detectors, and test article and instrument positioning systems have been added. The x-ray data acquisition system has been updated. A real-time position monitoring metrology system is being developed that will enable calibration of large diameter optics via partial illumination in a diverging beam. The newly expanded x-ray test capabilities of the facility will be discussed.
Electroforming replication technology at Marshall Space Flight Center has a long heritage of producing highquality full-shell X-ray mirrors for various applications. Nickel alloys are electroformed onto a super-polished mandrel in the electroforming process, then separated to form the replicated full-shell optic. Various parameters in the electroplating configuration could result in the nonuniformity of the shell’s thickness. Thickness nonuniformities primarily occur due to non-uniform electric field distributions in the electroforming tank during the deposition. Using COMSOL Multiphysics simulations, we have studied the electric field distributions during the deposition process. Using these studies, we have optimized the electric fields inside the tank using customized shields and insulating gaskets on the mandrel. These efforts reduced thickness non-uniformity from over 20% to under 5% percent. Improving the thickness uniformity of the shell aids in better mounting and alignment of shells in the optics module. Optimization of the electroforming process, in some cases, improved the optical performance of the shells. COMSOL optimizing of the electroforming process and the experimental results validating these simulations are presented in this article.