This annual review documents our progress towards inexpensive mass production of silicon carbide mirrors and optical
structures. Results are provided for a NASA Small Business Technology Transfer (STTR) X-Ray Mirror project. Trex
partnered with the University of Alabama-Huntsville Center for Advanced Optics (UAH-CAO) to develop fabrication
methods for polished cylindrical and conical chemical vapor composite (CVCTM) SiC mandrels. These mandrels are
envisioned as pre-forms for the replication of fused silica x-ray optics to be eventually used in the International X-Ray
Observatory (IXO). CVC SiCTM offers superior high temperature stability, thermal and mechanical performance and
polishability required for this precision replication process. In this program, Trex fabricated prototype mandrels with
design diameters of 10.5cm, 20cm and 45cm.
UAH-CAO was Trex's university partner in this effort and worked on polishing and metrology of the unusual x-ray
mandrel geometries. UAH-CAO successfully developed an innovative interferometric method for measuring the CVC
SiCTM x-ray mandrels based on a precision cylindrical lens system. UAH-CAO also developed finishing and polishing
methods for CVC SiCTM that utilized a Zeeko IRP200 computer controlled polishing tool. The three technologies key
technologies demonstrated in this program (near net shape forming of CVC SiCTM mandrels, the x-ray mandrel
metrology and free-form polishing capability on CVC SiCTM) could enable cost-effective manufacture of the x-ray
mandrels required for the International X-Ray Observatory (IXO).
KEYWORDS: Silicon carbide, Mirrors, Space telescopes, Chemical vapor deposition, Natural surfaces, Composites, Photovoltaics, Plano, Telescopes, James Webb Space Telescope
Components for space telescopes using high quality silicon carbide (SiC) produced via the chemical vapor composite (CVC) process are currently under development. This CVC process is a modification of chemical vapor deposition (CVD) and results in a dramatic reduction in residual stress of the SiC deposit. The resultant CVC SiC material has high modulus, high thermal conductivity and can be polished to better than 1nm RMS surface roughness, making it ideal for space telescopes requiring lightweight, stiff and thermally stable components. Moreover, due to its lower intrinsic stress, CVC SiC is much more readily scaled to large sizes and manufactured into the complex geometries needed for the telescope assemblies. Results are presented on the optical figure for a lightweight 15cm CVC SiC mirror demonstrating low wavefront error (<30nm peak-to-valley and <5.1nm rms). Theoretical and experimental modal analysis measured the first four resonant modes of the mirror and found a first modal frequency in the vicinity of 2100 Hz, representing a highly stiff mirror.
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