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Completed TRL 3 (started at 2, targeting 3)
Proposed is a micro-CIF program to study the cryogenic optical performance of vacuum brazed aluminum honeycomb panels with the goal of making large cryogenic mirrors that operate in the far-to-mid IR spectrum. For 2022, the NASA Astrophysics Program Office has identified “Large Cryogenic Optics for the Mid IR to Far IR” as a tier 1 technology gap. The specific objectives given for aluminum mirrors are the operating surface figure, amount of cryogenic surface deformation, first mode resonance, areal density, areal cost, and overall size. Vacuum brazing aluminum honeycomb panels is a mature technology that already meets these last four objectives. NASA can take advantage of the industry’s economy of scale to substantially reduce the cost of large IR mirrors. Currently unknown is the achievable surface figure and cryogenic performance. While the manufacturing readiness level is high, the "application is speculative" thus rating a TRL 2. As a first step, we propose quantifying the optical effect that differences in CTE have between the various alloys used in the panel’s construction. Tasks to complete within 4-6 months and under $50k are 1) Procure COTS flat panel samples (approx. 0.2 x 0.2 meters) of varying thickness and core densities; 2) Polish one side and create a kinematic mount for the reverse; 3) Measure with a 4-inch, 632.8 nm interferometer the surface figure at room temp. down to 20 K (measured in the small XRCF chamber at MSFC); and 4) Process data and deliver report. Based on the outcome, a potential follow-on program would be a sub-scale curved mirror. With “Full” CIF funding of ~$110k, this would involve process development and fabrication of a custom curved panel along with diamond turning the mirror face to the final figure. This micro-CIF proposal is a small investment in time and resources to quickly evaluate if vacuum brazed aluminum honeycomb panels merit additional research to address NASA’s tier 1 astrophysics technology gap.
Projective objectives are to 1) Characterize cryogenic surface deformation (down to 20 K) of vacuum brazed aluminum honeycomb panels of various configurations and 2) Compare results to Astrophysics Program Office desired goals and determine if further evaluation is recommended. The overall objective is to substantially reduce costs for mid to far IR mirrors larger than one meter in diameter. The "Large Cryogenic Optics for the Mid IR to Far IR" tier 1 technology gap identified by the Astrophysics Program Office lists an aggressive set of goals for aluminum mirrors that are needed to enable Far-IR Astrophysics Probe missions. The primary tech taxonomy is TX08.2.1 Mirror Systems followed by TX12.1.4 Materials for Extreme Env.
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