Treatments To Produce Stabilized Aluminum Mirrors for Cryogenic Uses

Five metallurgical treatments have been tested as means of stabilizing mirrors that are made of aluminum alloy 6061 and are intended for use in cryogenic applications. Aluminum alloy 6061 is favored as a mirror material by many scientists and engineers. Like other alloys, it shrinks upon cool-down from room temperature to cryogenic temperature. This shrinkage degrades the optical quality of the mirror surfaces. Hence, the metallurgical treatments were tested to determine which one could be most effective in minimizing the adverse optical effects of cooldown to cryogenic temperatures. Each of the five metallurgical treatments comprises a multistep process, the steps of which are interspersed with the steps of the mirror-fabrication process. The five metallurgical-treatment/fabrication.- process combinations were compared with each other and with a benchmark fabrication process, in which a mirror is made from an alloy blank by (1) symmetrical rough machining, (2) finish machining to within 0.006 in. (. 0.15 mm) of final dimensions, and finally (3) diamond turning to a mirror finish

Method for the Absolute Calibration of the Location and Orientation of Large-Format Detectors Using Laser Radar

A method of mapping pixel locations of a detector array includes measuring a location on the detector array, initiating a frame readout of the detector array, measuring a location of one or more metrology targets on the detector array, analyzing the frame readout to identify a pixel at the location on the detector array, and defining a location of the identified pixel with respect to the location of the one or more metrology targets. Subsequent measurement of the metrology targets alone by another metrology system allows one to infer the six degree of freedom alignment of the detector array in space

Alignment and Testing for a Freeform Telescope

Currently there is a strong desire to make Earth science less expensive. Freeform optics make these missions less expensive because they allow an optical designer to use fewer mirrors to create roughly the same effect. The main issue with using freeforms is how closely the substrate can be milled to its prescription. Over this summer, our team looked at two freeforms made by Corning Inc. using a brand new process to determine how close these optics are to their set prescriptions and how well NASA could align them

Measuring the In-Process Figure, Final Prescription, and System Alignment of Large Optics and Segmented Mirrors Using Lidar Metrology

The fabrication of large optics is traditionally a slow process, and fabrication capability is often limited by measurement capability. W hile techniques exist to measure mirror figure with nanometer precis ion, measurements of large-mirror prescription are typically limited to submillimeter accuracy. Using a lidar instrument enables one to measure the optical surface rough figure and prescription in virtuall y all phases of fabrication without moving the mirror from its polis hing setup. This technology improves the uncertainty of mirror presc ription measurement to the micron-regime

Pupil Alignment Considerations for Large, Deployable Space Telescopes

For many optical systems the properties and alignment of the internal apertures and pupils are not critical or controlled with high precision during optical system design, fabrication or assembly. In wide angle imaging systems, for instance, the entrance pupil position and orientation is typically unconstrained and varies over the system s field of view in order to optimize image quality. Aperture tolerances usually do not receive the same amount of scrutiny as optical surface aberrations or throughput characteristics because performance degradation is typically graceful with misalignment, generally only causing a slight reduction in system sensitivity due to vignetting. But for a large deployable space-based observatory like the James Webb Space Telescope (JWST), we have found that pupil alignment is a key parameter. For in addition to vignetting, JWST pupil errors cause uncertainty in the wavefront sensing process that is used to construct the observatory on-orbit. Furthermore they also open stray light paths that degrade the science return from some of the telescope s instrument channels. In response to these consequences, we have developed several pupil measurement techniques for the cryogenic vacuum test where JWST science instrument pupil alignment is verified. These approaches use pupil alignment references within the JWST science instruments; pupil imaging lenses in three science instrument channels; and unique pupil characterization features in the optical test equipment. This will allow us to verify and crosscheck the lateral pupil alignment of the JWST science instruments to approximately 1-2% of their pupil diameters

Diamond Machining of an Off-Axis Biconic Aspherical Mirror

Two diamond-machining methods have been developed as part of an effort to design and fabricate an off-axis, biconic ellipsoidal, concave aluminum mirror for an infrared spectrometer at the Kitt Peak National Observatory. Beyond this initial application, the methods can be expected to enable satisfaction of requirements for future instrument mirrors having increasingly complex (including asymmetrical), precise shapes that, heretofore, could not readily be fabricated by diamond machining or, in some cases, could not be fabricated at all. In the initial application, the mirror is prescribed, in terms of Cartesian coordinates x and y, by aperture dimensions of 94 by 76 mm, placements of -2 mm off axis in x and 227 mm off axis in y, an x radius of curvature of 377 mm, a y radius of curvature of 407 mm, an x conic constant of 0.078, and a y conic constant of 0.127. The aspect ratio of the mirror blank is about 6. One common, "diamond machining" process uses single-point diamond turning (SPDT). However, it is impossible to generate the required off-axis, biconic ellipsoidal shape by conventional SPDT because (1) rotational symmetry is an essential element of conventional SPDT and (2) the present off-axis biconic mirror shape lacks rotational symmetry. Following conventional practice, it would be necessary to make this mirror from a glass blank by computer-controlled polishing, which costs more than diamond machining and yields a mirror that is more difficult to mount to a metal bench. One of the two present diamond machining methods involves the use of an SPDT machine equipped with a fast tool servo (FTS). The SPDT machine is programmed to follow the rotationally symmetric asphere that best fits the desired off-axis, biconic ellipsoidal surface. The FTS is actuated in synchronism with the rotation of the SPDT machine to generate the difference between the desired surface and the best-fit rotationally symmetric asphere. In order to minimize the required stroke of the FTS, the blanks were positioned at a large off-axis distance and angle, and the axis of the FTS was not parallel to the axis of the spindle of the SPDT machine. The spindle was rotated at a speed of 120 rpm, and the maximum FTS speed was 8.2 mm/s

CGH Figure Testing of Aspherical Mirrors in Cold Vacuums

An established method of room-temperature interferometric null testing of mirrors having simple shapes (e.g., flat, spherical, or spheroidal) has been augmented to enable measurement of errors in the surface figures of off-axis, non-axisymmetric, aspherical mirrors when the mirrors are located inside cryogenic vacuum chambers. The established method involves the use of a computer-generated hologram (CGH), functionally equivalent to a traditional null lens, to modify the laser beam of an imaging interferometer to obtain a reference wavefront that matches the ideal surface figure of a mirror under test. The CGH is inserted at the appropriate position and orientation in the optical path of the imaging interferometer, which, in turn, is appropriately positioned and oriented with respect to the mirror under test. Deviations of the surface figure of the mirror from the ideal surface figure manifest themselves as interference fringes. Interferograms are recorded and analyzed to deduce figure errors

Large Stroke, Picometer Resolution Hexapod for Dynamic Mirror Positioning

Viewgraph presentation reviews the Fast Picometer Mirror mounting (FPMM) for the Terrestrial Planet Finder Coronagraph (TPF-C). Included in the presentation are slides with an overviews of the TPF-C, the requirements of the FPMM, the selection of the materials using the ACE system, and the architecture of the FPMM

Absolute Position of Targets Measured Through a Chamber Window Using Lidar Metrology Systems

Lidar is a useful tool for taking metrology measurements without the need for physical contact with the parts under test. Lidar instruments are aimed at a target using azimuth and elevation stages, then focus a beam of coherent, frequency modulated laser energy onto the target, such as the surface of a mechanical structure. Energy from the reflected beam is mixed with an optical reference signal that travels in a fiber path internal to the instrument, and the range to the target is calculated based on the difference in the frequency of the returned and reference signals. In cases when the parts are in extreme environments, additional steps need to be taken to separate the operator and lidar from that environment. A model has been developed that accurately reduces the lidar data to an absolute position and accounts for the three media in the testbed air, fused silica, and vacuum but the approach can be adapted for any environment or material. The accuracy of laser metrology measurements depends upon knowing the parameters of the media through which the measurement beam travels. Under normal conditions, this means knowledge of the temperature, pressure, and humidity of the air in the measurement volume. In the past, chamber windows have been used to separate the measuring device from the extreme environment within the chamber and still permit optical measurement, but, so far, only relative changes have been diagnosed. The ability to make accurate measurements through a window presents a challenge as there are a number of factors to consider. In the case of the lidar, the window will increase the time-of-flight of the laser beam causing a ranging error, and refract the direction of the beam causing angular positioning errors. In addition, differences in pressure, temperature, and humidity on each side of the window will cause slight atmospheric index changes and induce deformation and a refractive index gradient within the window. Also, since the window is a dispersive media, the effect of both phase and group indices have to be considered. Taking all these factors into account, a method was developed to measure targets through multiple regions of different materials and produce results that are absolute measurements of target position in three-dimensional space, rather than simply relative position. The environment in which the lidar measurements are taken must be broken down into separate regions of interest and each region solved for separately. In this case, there were three regions of interest: air, fused silica, and vacuum. The angular position of the target inside the chamber is solved using only phase index and phase velocity, while the ranging effects due to travel from air to glass to vacuum/air are solved with group index and group velocity. When all parameters are solved simultaneously, an absolute knowledge of the position of each target within an environmental chamber can be derived. Novel features of this innovation include measuring absolute position of targets through multiple dispersive and non-dispersive media, deconstruction of lidar raw data from a commercial off-the-shelf unit into reworkable parameters, and use of group velocities to reduce range data. Measurement of structures within a vacuum chamber or other harsh environment, such as a furnace, may now be measured as easily as if they were in an ambient laboratory. This analysis permits transformation of the raw data into absolute spatial units (e.g., mm). This technique has also been extended to laser tracker, theodolite, and cathetometer measurements through refractive media

Universal and Automated Monte Carlo Method Code for Uncertainty Propagation in Metrology Databases

A method of providing transformed target points for integrating a component into an assembly includes collecting a set of component target points, collecting a set of assembly target points, identifying target points common to the set of component target points and the set of assembly target points; performing a specified number of Monte Carlo transformations of selected ones of the common target points to yield a set of transformed target points and vectors and an associated uncertainty value for each transformed target point and vector, and using certain ones of the transformed target points for integrating the component into the assembly based on the associated uncertainty value for each of the transformed target points