Machining process of lightweight AlSi10Mg optical mirror based on additive manufacturing substrate

Yifan Wang; Jun Yu; Zhengxiang Shen; Qiushi Huang; Bin Ma; Zhong Zhang; Zhanshan Wang

doi:10.1117/12.2603970

13 December 2021 Machining process of lightweight AlSi10Mg optical mirror based on additive manufacturing substrate

Yifan Wang, Jun Yu, Zhengxiang Shen, Qiushi Huang, Bin Ma, Zhong Zhang, Zhanshan Wang

Proceedings Volume 12073, 10th International Symposium on Advanced Optical Manufacturing and Testing Technologies: Advanced and Extreme Micro-Nano Manufacturing Technologies; 120730I (2021) https://doi.org/10.1117/12.2603970
Event: Tenth International Symposium on Advanced Optical Manufacturing and Testing Technologies (AOMATT 2021), 2021, Chengdu, China

Abstract

Aluminum alloy mirror by additive manufacturing (AM) has attracted much attention in recent years because of its excellent strength, machinability, and high design freedom. This paper describes the machining process of lightweight mirror based on AM AlSi10Mg body. The mirror is processed to the accuracy of 45.6 nm in RMS, and the surface roughness reaches 0.585 nm in Rq. Initially, the mirror substrate is processed using selective laser melting (SLM) with AlSi10Mg powders. Then the backside surfaces and optical front surface of the mirror substrate are processed by CNC turning and single-point diamond turning (SPDT). After the Nickel-Phosphorus (NiP) coating is electroplated, ultra-precision machining is used to process the optical surface finally, in which, SPDT and magnetorheological finishing (MRF) is used to ensure the surface accuracy. Then subsequent polishing eliminated low frequency stripes and MRF marks, significantly reducing the roughness. In addition, the thorough release of internal stress is an important factor to ensure the stability of the surface accuracy. The experiment results prove that the process chain can satisfy the ultra-precision fabrication of infrared optical surface and the roughness has the potential to be applied in ultraviolet optical system.

Citation Download Citation

Yifan Wang, Jun Yu, Zhengxiang Shen, Qiushi Huang, Bin Ma, Zhong Zhang, and Zhanshan Wang "Machining process of lightweight AlSi10Mg optical mirror based on additive manufacturing substrate", Proc. SPIE 12073, 10th International Symposium on Advanced Optical Manufacturing and Testing Technologies: Advanced and Extreme Micro-Nano Manufacturing Technologies, 120730I (13 December 2021); https://doi.org/10.1117/12.2603970

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KEYWORDS

Mirrors

Single point diamond turning

Surface finishing

Magnetorheological finishing

Additive manufacturing

Lightweight mirrors

Optics manufacturing

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