Contributions of kinematics and viscoelastic lap deformation on the suface figure during full aperture polishing of fused silica

A typical optical fabrication process involves a series of basic process steps including: (1) shaping, (2) grinding, (3) polishing, and sometimes (4) sub-aperture tool finishing. With significant innovation and development over the years in both the front end (shaping using CNC machines) and the back end (sup-aperture tool polishing), these processes have become much more deterministic. However, the intermediate stages (full aperture grinding/polishing) in the process, which can be very time consuming, still have much reliance on the optician's insight to get to the desired surface figure. Such processes are not presently very deterministic (i.e. require multiple iterations to get desired figure). The ability to deterministically finish an optical surface using a full aperture grinding/polishing will aid optical glass fabricators to achieve desired figure in a more repeatable, less iterative, and more economical manner. Developing a scientific understanding of the material removal rate is a critical step in accomplishing this. In the present study, the surface figure and material removal rate of a fused silica workpiece is measured as a function of polishing time using Ceria based slurry on a polyurethane pad or pitch lap under a variety of kinematic conditions (motion of the workpiece and lap) and loading configurations. The measured results have been applied to expand the Preston model of material removal (utilizing chemical, mechanical and tribological effects). The results show that under uniform loading, the surface figure is dominated by kinematics which can be predicted by calculating the relative velocity (between the workpiece and the lap) with time and position on the workpiece. However, in the case where the kinematics predict a time-averaged removal function over the workpiece that is uniform, we find experimentally that the surface deviates significantly from uniform removal. We show that this non-uniform removal is caused by the non-uniform stress distribution resulting from the viscoelastic nature of the lap. The viscoelastic lap results in a strain difference across the part due to a time dependent deformation of the lap as it travels pass the workpiece. A quantitative viscoelastic model has been developed to explain this effect. The effects of the viscoelastic lap on the removal function can be removed by pre-straining the lap before it contacts the workpiece which have shown better than l/4 surfaces being maintained with continuous removal

Scratch Forensics

Scratches on optical components which are formed during fabrication, cleaning, handling and end-use, are widespread and almost always detrimental. The impact of scratches on the end-use of the optic includes increased optical scatter, reduced system performance, and reduced strength. In the case of optics used in high intensity laser applications, prevention of scratches is paramount because they are closely associated with laser damage. Evaluation of the characteristics (dimensions, location on optic, shape, and orientation) of a scratch can serve a powerful tool to identify the cause of the scratch and lead to mitigations to prevent their reoccurrence. It is likely that opticians have used such techniques for hundreds of years. In recent years, by applying techniques of fracture mechanics and tribology, several new semi-quantitative rules-of-thumb have been developed allowing one to estimate the size and shape of the scratch inducing asperity or rogue particle, the load on the particle, the depth of the fractures in the scratch, and properties of material housing the rogue particle. The following discussion reviews some these techniques, which as a whole, we refer to as 'Scratch Forsenics'

MRF Applications: Measurement of Process-dependent Subsurface Damage in Optical Materials using the MRF Wedge Technique

Understanding the behavior of fractures and subsurface damage in the processes used during optic fabrication plays a key role in determining the final quality of the optical surface finish. During the early stages of surface preparation, brittle grinding processes induce fractures at or near an optical surface whose range can extend from depths of a few mm to hundreds of mm depending upon the process and tooling being employed. Controlling the occurrence, structure, and propagation of these sites during subsequent grinding and polishing operations is highly desirable if one wishes to obtain high-quality surfaces that are free of such artifacts. Over the past year, our team has made significant strides in developing a diagnostic technique that combines magnetorheological finishing (MRF) and scanning optical microscopy to measure and characterize subsurface damage in optical materials. The technique takes advantage of the unique nature of MRF to polish a prescribed large-area wedge into the optical surface without propagating existing damage or introducing new damage. The polished wedge is then analyzed to quantify subsurface damage as a function of depth from the original surface. Large-area measurement using scanning optical microscopy provides for improved accuracy and reliability over methods such as the COM ball-dimple technique. Examples of the technique's use will be presented that illustrate the behavior of subsurface damage in fused silica that arises during a variety of intermediate optical fabrication process steps

Utilization of Magnetorheological Finishing as a Diagnostic Tool for Investigating the Three-Dimensional Structure of Fractures in Fused Silica

We have developed an experimental technique that combines magnetorheological finishing (MRF) and microscopy to examine fractures and/or artifacts in optical materials. The technique can be readily used to provide access to, and interrogation of, a selected segment of a fracture or object that extends beneath the surface. Depth slicing, or cross-sectioning at selected intervals, further allows the observation and measurement of the three-dimensional nature of the sites and the generation of volumetric representations that can be used to quantify shape and depth, and to understand how they were created, how they interact with surrounding material, and how they may be eliminated or mitigated

Effect of rogue particles on the sub-surface damage of fused silica during grinding/polishing

The distribution and characteristics of surface cracks (i.e., sub-surface damage or scratching) on fused silica formed during grinding/polishing resulting from the addition of rogue particles in the base slurry has been investigated. Fused silica samples (10 cm diameter x 1 cm thick) were: (1) ground by loose abrasive grinding (alumina particles 9-30 {micro}m) on a glass lap with the addition of larger alumina particles at various concentrations with mean sizes ranging from 15-30 {micro}m, or (2) polished (using 0.5 {micro}m cerium oxide slurry) on various laps (polyurethanes pads or pitch) with the addition of larger rogue particles (diamond (4-45 {micro}m), pitch, dust, or dried Ceria slurry agglomerates) at various concentrations. For the resulting ground samples, the crack distributions of the as-prepared surfaces were determined using a polished taper technique. The crack depth was observed to: (1) increase at small concentrations (>10{sup -4} fraction) of rogue particles; and (2) increase with rogue particle concentration to crack depths consistent with that observed when grinding with particles the size of the rogue particles alone. For the polished samples, which were subsequently etched in HF:NH{sub 4}F to expose the surface damage, the resulting scratch properties (type, number density, width, and length) were characterized. The number density of scratches increased exponentially with the size of the rogue diamond at a fixed rogue diamond concentration suggesting that larger particles are more likely to lead to scratching. The length of the scratch was found to increase with rogue particle size, increase with lap viscosity, and decrease with applied load. At high diamond concentrations, the type of scratch transitioned from brittle to ductile and the length of the scratches dramatically increased and extended to the edge of the optic. The observed trends can explained semi-quantitatively in terms of the time needed for a rogue particle to penetrate into a viscoelastic lap. The results of this study provide useful insights and 'rules-of-thumb' relating scratch characteristics observed on surfaces during optical glass fabrication to the characteristics rogue particles causing them and their possible source

The distribution of subsurface damage in fused silica

Managing subsurface damage during the shaping process and removing subsurface damage during the polishing process is essential in the production of low damage density optical components, such as those required for use on high peak power lasers. Removal of subsurface damage, during the polishing process, requires polishing to a depth which is greater than the depth of the residual cracks present following the shaping process. To successfully manage, and ultimately remove subsurface damage, understanding the distribution and character of fractures in the subsurface region introduced during fabrication process is important. We have characterized the depth and morphology of subsurface fractures present following fixed abrasive and loose abrasive grinding processes. At shallow depths lateral cracks and an overlapping series of trailing indentation fractures were found to be present. At greater depths, subsurface damage consists of a series of trailing indentation fractures. The area density of trailing fractures changes as a function of depth, however the length and shape of individual cracks remain nearly constant for a given grinding process. We have developed and applied a model to interpret the depth and crack length distributions of subsurface surface damage in terms of key variables including abrasive size and load

Sub-surface mechanical damage distributions during grinding of fused silica

The distribution and characteristics of surface cracking (i.e. sub-surface damage or SSD) formed during standard grinding processes has been investigated on fused silica glass. The SSD distributions of the ground surfaces were determined by: (1) creating a shallow (18-108 {micro}m) wedge/taper on the surface by magneto-rheological finishing; (2) exposing the SSD by HF acid etching; and (3) performing image analysis of the observed cracks from optical micrographs taken along the surface taper. The observed surface cracks are characterized as near-surface lateral and deeper trailing indent type fractures (i.e., chatter marks). The SSD depth distributions are typically described by a single exponential distribution followed by an asymptotic cutoff in depth (c{sub max}). The length of the trailing indent is strongly correlated with a given process. Using established fracture indentation relationships, it is shown that only a small fraction of the abrasive particles are being mechanically loaded and causing fracture, and it is likely the larger particles in the abrasive particle size distribution that bear the higher loads. The SSD depth was observed to increase with load and with a small amount of larger contaminant particles. Using a simple brittle fracture model for grinding, the SSD depth distribution has been related to the SSD length distribution to gain insight into ''effective'' size distribution of particles participating in the fracture. Both the average crack length and the surface roughness were found to scale linearly with the maximum SSD depth (c{sub max}). These relationships can serve as useful rules-of-thumb for nondestructively estimating SSD depth and to identify the process that caused the SSD. In certain applications such as high intensity lasers, SSD on the glass optics can serve as a reservoir for minute amounts of impurities that absorb the high intensity laser light and lead to subsequent laser-induced surface damage. Hence a more scientific understanding of SSD formation can provide a means to establish recipes to fabricate SSD-free, laser damage resistant optical surfaces

Lawson criterion for ignition exceeded in an inertial fusion experiment

For more than half a century, researchers around the world have been engaged in attempts to achieve fusion ignition as a proof of principle of various fusion concepts. Following the Lawson criterion, an ignited plasma is one where the fusion heating power is high enough to overcome all the physical processes that cool the fusion plasma, creating a positive thermodynamic feedback loop with rapidly increasing temperature. In inertially confined fusion, ignition is a state where the fusion plasma can begin "burn propagation" into surrounding cold fuel, enabling the possibility of high energy gain. While "scientific breakeven" (i.e., unity target gain) has not yet been achieved (here target gain is 0.72, 1.37 MJ of fusion for 1.92 MJ of laser energy), this Letter reports the first controlled fusion experiment, using laser indirect drive, on the National Ignition Facility to produce capsule gain (here 5.8) and reach ignition by nine different formulations of the Lawson criterion

Material Removal and Surface Figure During pad Polishing of Fused Silica

Abstract The material removal and surface figure after ceria pad polishing of fused silica glass have been measured and analyzed as a function of kinematics, loading conditions, and polishing time. Also, the friction at the workpiece/lap interface, the slope of the workpiece relative to the lap plane, and lap viscoelastic properties have been measured and correlated to material removal. The results show that the relative velocity between the workpiece & lap (determined by the kinematics) and the pressure distribution determine the spatial and temporal material removal and hence the final surface figure of the workpiece. In the case where the applied loading and relative velocity distribution over the workpiece are spatially uniform, a significant non-uniform spatial material removal from the workpiece surface is observed. This is due to a non-uniform pressure distribution resulting from: 1) a moment caused by a pivot point and interface friction forces; 2) viscoelastic relaxation of the polyurethane lap; and 3) a physical workpiece/lap interface mismatch. Both the kinematics and these contributions to the pressure distribution are quantitatively described, and then . The surface figure simulations are consistent with the experiment for a wide variety of polishing conditions. This study is an important step towards deterministic full-aperture polishing, which would allow optical glass fabrication to be performed in a more repeatable, less iterative, and hence more economical manner