Optimizing the electroforming process to enhance the thickness uniformity of full shell x-ray optics

Panini Singam; Chet Speegle; Amy Meekham; Jeffery Kolodziejczak; Wayne Baumgartner; Grant Davis; David Banks; Jessica Gaskin; Stephen Bongiorno; Brian Ramsey

doi:10.1117/12.2677698

5 October 2023 Optimizing the electroforming process to enhance the thickness uniformity of full shell x-ray optics

Panini Singam, Chet Speegle, Amy Meekham, Jeffery Kolodziejczak, Wayne Baumgartner, Grant Davis, David Banks, Jessica Gaskin, Stephen Bongiorno, Brian Ramsey

Author Affiliations +

Proceedings Volume 12679, Optics for EUV, X-Ray, and Gamma-Ray Astronomy XI; 126790B (2023) https://doi.org/10.1117/12.2677698
Event: SPIE Optical Engineering + Applications, 2023, San Diego, California, United States

Abstract

Electroforming replication technology at Marshall Space Flight Center has a long heritage of producing high-quality full-shell x-ray mirrors for various applications. Nickel alloys are electroformed onto a super-polished mandrel in the electroforming process, then separated to form the replicated full-shell optic. Various parameters in the electroplating configuration could result in the nonuniformity of the shell’s thickness. Thickness non-uniformities primarily occur due to non-uniform electric field distributions in the electroforming tank during the deposition. Using COMSOL Multiphysics simulations, we have studied the electric field distributions during the deposition process. Using these studies, we have optimized the electric fields inside the tank using customized shields and insulating gaskets on the mandrel. These efforts reduced thickness non-uniformity from over 20% to under 5% percent. Improving the thickness uniformity of the shell aids in better mounting and alignment of shells in the optics module. Optimization of the electroforming process, in some cases, improved the optical performance of the shells. COMSOL optimizing of the electroforming process and the experimental results validating these simulations are presented in this article.

Conference Presentation

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Panini Singam, Chet Speegle, Amy Meekham, Jeffery Kolodziejczak, Wayne Baumgartner, Grant Davis, David Banks, Jessica Gaskin, Stephen Bongiorno, and Brian Ramsey "Optimizing the electroforming process to enhance the thickness uniformity of full shell x-ray optics", Proc. SPIE 12679, Optics for EUV, X-Ray, and Gamma-Ray Astronomy XI, 126790B (5 October 2023); https://doi.org/10.1117/12.2677698

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