Evaluation of deflectometry for E-ELT optics

A deflectometrical facility was developed at Italian National Institute for Astrophysics-OAB in the context of the ASTRI project to characterize free-form segments for Cherenkov optics. The test works as an inverse Ronchi test in combination with a ray-tracing code: the under-test surface is illuminated by a known light pattern and the pattern warped by local surface errors is observed. Knowing the geometry of the system it is possible to retrieve the surface normal vectors. This contribution presents the analysis of the upgrades and of the configuration modifications required to allow the use of deflectometry in the realization of optical components suitable for European Extremely Large Telescope and as a specific case to support the manufacturing of the Multi-conjugate Adaptive Optics Relay (MAORY) module. <P /

Metrological needs and reliable solutions for optics fabrication related to E-ELT

In order to contribute and support the R&D activities related to the E-ELT (European Extremely Large Telescope) program, the INAF-OAB acquired a dedicated robotic polisher machine, the IRP1200 by Zeeko. It will be used in synergy with the ion beam figuring technique, already available at OAB for the realization of prototypes and advanced optical components, as the optics of the Multi-conjugate Adaptive Optics Relay module (MAORY). In this paper, starting from the discussion of the metrological needs to be fulfilled during the different parts of the machining for the different kind of optics, we define the metrological scheme that will be followed. Moreover, we present the concept for a new measurement machine based of non-contact scanning probes, capable of nanometer uncertainty and compatible with the optics design to be realized. škip 0.5c

A bonnet and fluid jet polishing facility for optics fabrication related to the E-ELT

A robotic polishing machine has been implemented at INAF-Brera Astronomical Observatory within the T-REX project. The facility, IRP1200 by Zeeko Ltd., consists of a 7-axis computer-controlled polishing/forming machine capable of producing precision surfaces on several optical materials. The machine enables two methods, the bonnet and the fluid jet polishing. We report on the results of the standard bonnet polishing machine acceptance tests that have been completed at our site. We intend to use the machine to support development and production programs related to the European Extremely Large Telescope (E-ELT), in particular, for making part of the optics of the Multi-conjugate Adaptive Optics RelaY (MAORY) module. <P /

Ion beam figuring technique used as final step in the manufacturing of the optics for the E-ELT

The INAF-Astronomical Observatory of Brera (INAF-OAB) is exploring the technical problems related to the ion beam figuring (IBF) of the Zerodur hexagonal mirrors (1.45 m corner to corner) of M1 for the European Extremely Large Telescope (E-ELT). As starting step a scaled down version mirror of the same material having size of 1 m corner to corner has been used to assess the relevant figuring problems. This specific mirror is spherical and has a radius of curvature of 3 m which allows a simple interferometric measurement setup. A mechanical support was designed to minimize its deformations due to gravity. The Ion Beam Figuring Facility used for this study has been recently completed in the Brera Observatory and has a figuring area of 170 cm x 140 cm. Aim of this study is the estimation and optimization of the time requested for the correction of the surface using also strategies to control the well-known thermal problems related to the Zerodur material. In this paper we report the results obtained figuring the 1 m corner-to-corner test segment

Cold shaping of thin glass foils: a fast and cost-effective solution for making light-weight astronomical x-ray optics

Recent advancements in thin glass materials allowed the development and the mass production of very thin glass foils, like e.g. the Willow glass (thickness of 0.1-0.2 mm) produced by Corning or AF32 produced by Schott (thickness down to 0.055 mm). The thickness, strength and flexibility of these glass foils allow bending them up to very small radius of curvature without breaks. This feature, together with the very low micro-roughness, makes this kind of materials ideal candidates for pursuing a cold replication approach for cost-effective and fast making of grazing incidence astronomical optics. Starting from the very thin flat glass sheets, the process under development foresees to bond them onto the supporting structure while they are wrapped around reference mandrels. The assembly concept, based on the use of Wolter-I counter-form moulds, is also based on the use of reinforcing ribs that connect pairs of consecutive foils in the final assembly. The ribs do not only play the role of mechanical connectors, they keep the shape and increase the structural stiffness. Indeed, the ribs constrain the foil profile to the correct shape during the bonding, damping the low-frequency residuals with respect to the Wolter I configuration. This approach is particularly interesting because of their low weight and cost. They could e.g be used for the production of high throughput optics as those needed for the Chines XTP mission, in which the requirements on the angular resolution are not too tight. In fact, a Half Energy Width in the range of 20-60 arcsec is compatible with the expected residual error due to the spring back of the glass sheets. In this paper we provide an overview of the project, the expected performances and present the first preliminary results

Thin fused silica shells for high-resolution and large collecting area x-ray telescopes (like Lynx/XRS)

The implementation of an X-ray mission with high imaging capabilities, similar to those achieved with Chandra (2 effective area @1 keV), represents a compelling request by the scientific community. To this end the Lynx/XRS mission is being studied in USA, with the participation of international partners. In order to figure out the challenging technological task of the mirror fabrication, different approaches are considered, based on monolithic and segmented shells. Starting from the experience done on the glass prototypal shell realized in the past years, the direct polishing of thin (2 mm thick) fused silica monolithic shells is being investigated as a possible solution. A temporary stiffening structure is designed to support the shell during the figuring and polishing operations and to manage the handling up to its integration in the telescope structure. After the grinding and the polishing phases, in order to achieve the required surface accuracy, a final ion beam figuring correction is foreseen. In this paper, we present the technological process and the results achieved so far on a prototypal shell under development

Direct hot slumping of thin glass foils for future generation x-ray telescopes: current state of the art and future outlooks

To significantly improve the performances of the current X-ray observatories, the next generation of X-ray telescopes has to be characterized by a large effective area (Aeff { 2 m2 at 1 keV) and angular resolution better than 5 arcsec. The large dimension implied by these requirements forces the use of a modular approach, splitting the optics into segments. Moreover, lightweight materials, such as glass, have to be selected for the segmented optics in order to maintain a manageable weight for the optics. Since 2009 we are developing a direct hot slumping technique assisted by pressure, in which the glass optical surface is in contact with the mould and a pressure is applied in order to force the glass to copy the mould shape. A cold slumping step is used then to integrate the mirror segments into the final Wolter-I configuration. We present the state of the art of our hot slumping technology, comparing the results obtained with different glass types and mould materials. We also provide an overview of the possibilities of this technology also in view of future developments

Slumped glass foils as substrate for adjustable x-ray optics

Thin glass modular mirrors are a viable solution to build future X-ray telescopes with high angular resolution and large collecting area. In our laboratories, we shape thin glass foils by hot slumping and we apply pressure to assist the replication of a cylindrical mould figure; this technology is coupled with an integration process able to damp low frequency errors and produces optics in the Wolter I configuration, typical for the X-ray telescopes. From the point of view of the hot slumping process, the efforts were focused in reducing low-, mid- and high- frequency errors of the formed Eagle glass foils. Some of our slumped glass foils were used for the development of active X-ray optics, where piezoelectric actuators are used to correct the slumped glass foil deviations from the ideal shape. In particular, they were used for the Adjustable X-raY optics for astrOnoMy project (AXYOM) developed in Italy, and the X-ray Surveyor mission, as developed at the Smithsonian Astrophysical Observatory / Center for Astrophysics (SAO/CfA) in USA. In this paper we describe the optimisation of the hot slumping process, comparing the results with the requirements of the considered active optics projects. Finally, since the present configuration of the Pennsylvania State University (PSU) coating equipment is limited to 100 x 100 mm2, the slumped glass foils used for the SAO project were cut from 200 x 200 mm2 to 100 x 100 mm2, and a low-frequency change was observed. A characterisation of the profile change upon cutting is presented