NASA SBIR 2011 Solicitation


PROPOSAL NUMBER: 11-1 S2.04-9735
SUBTOPIC TITLE: Advanced Optical Component Systems
PROPOSAL TITLE: Diamond Turned Super Alloy Mandrel for Slump Forming X-Ray Observatory (IXO) Mirrors

SMALL BUSINESS CONCERN (Firm Name, Mail Address, City/State/Zip, Phone)
Dallas Optical Systems, Inc.
1790 Connie Lane
Rockwall, TX 75032 - 6708
(972) 564-1156

PRINCIPAL INVESTIGATOR/PROJECT MANAGER (Name, E-mail, Mail Address, City/State/Zip, Phone)
John Casstevens
1790 Connie Lane
Rockwall, TX 75032 - 6708
(972) 564-1156

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 5

TECHNICAL ABSTRACT (Limit 2000 characters, approximately 200 words)
Diamond turning is proven to be able to quickly produce highly aspheric grazing incidence optical contours to visible wavelength tolerances with extremely smooth surfaces.

Super alloys with exceptional dimensional stability and strength under cyclic high temperatures have been developed for gas turbine engines. The thermal expansion can be in the range of the expansion of the borosilicate glasses used for X-Ray mirrors.

This proposal utilizes an existing manufacturing learning curve to develop a reliable material and manufacturing process for glass slumping mandrels. This development process will involve the following investigations and development goals :

-develop electroless nickel plating processes for super alloys,
-ultra precision machining and polishability of super alloys.
-diamond turning of electroless nickel before and after the slumping heat cycle.
-heat treatment for dimensional stability under thermal cycling.
-evaluation of oxidation of directly polished super alloys.
-evaluation of oxidation of polished electroless nickel.

Heat treatment and plating processes will be evaluated by producing a number of flat test mirror samples which will be measured optically before and after the glass slumping process to evaluate contour distortion, oxidation resistance, increase in surface roughness, and diamond machineability of the electroless nickel plating. A test slumping mandrel will be designed for fabrication in a Phase II SBIR.

POTENTIAL NASA COMMERCIAL APPLICATIONS (Limit 1500 characters, approximately 150 words)
With current technology, the cost to fabricate and the time to produce large mirrors is one of the limiting factors for many missions. A major emphasis in achieving a successful IXO is reducing the cost of the grazing incidence mirrors.

Diamond turning is proven to be able to quickly produce highly aspheric grazing incidence optical contours to visible wavelength tolerances with extremely smooth surfaces.

Because diamond turning can produce mandrels with extremely repeatable contour accuracy, the process allows manufacture of mandrels which can be adjusted in dimension to compensate for the thermal expansion of the borosilicate glass and the mandrel so that the curvature of the slumped glass can be adjusted. Any number of slumping mandrels can be produced with exactly the same contour with repeatability of approximately 1/100 wave visible light. This uniformity and rapidity of production of a relatively low cost mandrel will be enabling technology for IXO mirror fabrication.

POTENTIAL NON-NASA COMMERCIAL APPLICATIONS (Limit 1500 characters, approximately 150 words)
Diamond turned electroless nickel plated mirrors are in wide use in commercial and military applications. Molds for injection and compression molding of plastic and glass optics and other products utilize diamond turned electroless nickel plated molds. Electroless nickel plated mirrors are used for synchrotron light source installations around the world. Mandrels for slump forming of x-ray mirror optical segments will lower costs to the point of enabling large space borne x-ray optical instruments.

TECHNOLOGY TAXONOMY MAPPING (NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.)
Analytical Instruments (Solid, Liquid, Gas, Plasma, Energy; see also Sensors)
Coatings/Surface Treatments
Interferometric (see also Analysis)
Ionizing Radiation
Lasers (Ladar/Lidar)
Lasers (Measuring/Sensing)
Lasers (Medical Imaging)
Lasers (Weapons)
Materials & Structures (including Optoelectronics)
Microfabrication (and smaller; see also Electronics; Mechanical Systems; Photonics)
Optical/Photonic (see also Photonics)
Processing Methods
Spacecraft Design, Construction, Testing, & Performance (see also Engineering; Testing & Evaluation)
Telescope Arrays
Terahertz (Sub-millimeter)
X-rays/Gamma Rays

Form Generated on 11-22-11 13:43