Wolter mirrors for x-ray telescopes is fabricated through nickel electroforming process. Although the sufficient imaging ability has been confirmed through both x-ray focusing experiments and ray-trace analysis, there are still surface figure errors that need to be removed to improve the resolving power. We propose a new figure correction method combining Si coating on the mirror surface and Si removal processing. To implement this method, we have developed an inner surface profile measurement system. This system involves three non-contact laser probes that are scanned by a motorized stage. Two of the probes are used for compensating motion errors of the scanning stage. This method enables us to measure a one-dimensional figure error profile of the Wolter mirrors with a reproducibility on the order of single nanometers.
Large Wolter mirrors fabricated by high-precision Ni electroforming process have been used for x-ray telescopes. Since the replication accuracy of these mirrors is on the order of 100 nm, the surface figure correction is necessary for improving the figure accuracy. Recently, we have proposed a new figure correction scheme utilizing a Si layer on the mirror surface. The thickness of Si film can be measured with accuracy at a 1 nm level by a thickness measurement gauge, and Si removal process will be applied so that the figure error is reduced. In this study, we developed the DC magnetron sputtering system especially for depositing a Si on the inner surface of the Wolter mirror. By optimizing the parameters such as Ar gas pressure and the sputter power, we demonstrated a coating of uniform Si layer on the Wolter mirror. The uniform Si layer with a thickness of 90 nm was successfully produced with an accuracy of ±10 nm in PV(Peak-to-Valley). The uniformity of the deposition using this method was 10 nm of PV(Peak-to-Valley).
Wolter mirrors work as imaging optics of X-ray telescopes. We have been developing a Wolter mirror for the FOXSI-4 project in 2023 using a high-precision Ni electroforming process. The figure accuracy of mirrors is one of the main factors determining the spatial resolution in X-ray imaging. In this study, we optimized the electrodeposition conditions from the viewpoint of the uniformity of film thickness. The simulation model was developed to correctly predict the film thickness distribution before fabrication, whose parameters and boundary conditions were determined through electrochemical experiments. The model calculates the distribution of current density on the surface of the cathode by finite element analysis. In this paper, we report the current status of the electroforming process specializing in Wolter mirrors in X-ray telescopes.
For many years, Wolter mirrors have been used as imaging elements in X-ray telescopes. The shape error of Wolter mirrors fabricated by replicating the shape of a mandrel originates from the replication error in electroforming. We have been developing an X-ray focusing mirror for synchrotron radiation X-rays, as well as a high-precision electroforming process. In this paper, we report on the application of the advanced electroforming process to the fabrication of Wolter mirrors for the FOXSI Sun observation project. We also discuss the figuring accuracy of the mandrel.
We had been developing replicated aluminum foil optics for previous missions such as ASCA, Suzaku, and, Hitomi. This sort of X-ray optics can be lighter but the angular resolution is limited to on the order of arcminutes. Thus, to improve the angular resolution with light performances, we have started developing electro formed X-ray optics. Electroforming is a technology that can transfer to a substrate with high accuracy by plating the nano-level structure of a super-precision master and makes it easier to fabricate Wolter type-I shaped two-stage full-shell mirrors.
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