NASA / MSFC has made new full-shell NiCo replicated hard X-ray optics
for the fourth flight of the Focusing Optics X-ray Solar Imager
sounding rocket set to observe the sun in March 2023. The new FOXSI-4
high resolution optics were made using enhanced
mandrel polishing techniques incorporating a Zeeko CNC deterministic
polishing machine and an improved module assembly station with in-situ metrology.
FOXSI-4 will fly three new 2-meter focal length high
resolution mirror modules with two shells each. The previous FOXSI-3
optics achieved an angular resolution of 20 arcsec HPD (5 arcsec FWHM) for
ten-shell modules. Initial X-ray measurements of FOXSI-4 shells
before module integration show a performance of 8 arcsec HPD and 3
arcsec FWHM, a substantial improvement over the FOXSI-3 optics. We present the
advances made in the polishing, replication, and assembly processes, and
measurements of the performance of the completed modules taken in the
Marshall 100 meter X-ray beam line.
Technology for a large-area, high-angular resolution mirror module for a future Great Observatory x-ray mission is progressing along different paths. To date, none of these are fully developed. Work at the Marshall Space Flight Center (MSFC) seeks to leverage the benefits of full shell optics while exploring the limits of using shell replication technology for optics production. Here, we provide an updated accounting of spatial-resolution-constraining error terms to give context to recent improvements in MSFC replicated optics, as well as guidance and justification for current and future directions of research and development. Content includes straw-man error allocations for an optical system that is parametrically Lynx-like, where the replicated-optics technology stands relative to these allocations, and methodology for mapping development plans to efficiently identify the limiting factors, and approaches to overcoming these.
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.
The Imaging X-ray Polarimetry Explorer, a NASA small explorer mission, will be the first mission dedicated to x-ray polarimetry. The payload consists of three identical telescopes, each comprising a mirror module assembly (MMA) with a polarization-sensitive detector at its focus. We describe all aspects of the MMA, from initial optical and mechanical design considerations to meet program requirements through mirror shell fabrication, mirror shell integration and module assembly, environmental testing, x-ray calibration, and on-ground and on-orbit alignment.
Launched on 2021 December 9, the Imaging X-ray Polarimetry Explorer (IXPE) is a NASA Small Explorer Mission in collaboration with the Italian Space Agency (ASI). The mission will open a new window of investigation—imaging x-ray polarimetry. The observatory features three identical telescopes, each consisting of a mirror module assembly with a polarization-sensitive imaging x-ray detector at the focus. A coilable boom, deployed on orbit, provides the necessary 4-m focal length. The observatory utilizes a three-axis-stabilized spacecraft, which provides services such as power, attitude determination and control, commanding, and telemetry to the ground. During its 2-year baseline mission, IXPE will conduct precise polarimetry for samples of multiple categories of x-ray sources, with follow-on observations of selected targets.
Scheduled to launch in late 2021 the Imaging X-ray Polarimetry Explorer (IXPE) is a Small Explorer Mission designed to open up a new window of investigation -- X-ray polarimetry. The IXPE observatory features 3 identical telescope each consisting of a mirror module assembly with a polarization-sensitive imaging x-ray detector at its focus. An extending beam, deployed on orbit provides the necessary 4 m focal length. The payload sits atop a 3-axis stabilized spacecraft which among other things provides power, attitude determination and control, commanding, and telemetry to the ground. During its 2-year baseline mission, IXPE will conduct precise polarimetry for samples of multiple categories of x-ray sources, with follow-on observations of selected targets. IXPE is a partnership between NASA and the Italian Space Agency (ASI).
IXPE, the Imaging X-ray Polarimetry Explorer, is a NASA SMEX mission with an important contribution of ASI that will be launched with a Falcon 9 in 2021 and will reopen the window of X-ray polarimetry after more than 40 years. The payload features three identical telescopes each one hosting one light-weight X-ray mirror fabricated by MSFC and one detector unit with its in-orbit calibration system and the Gas Pixel Detector sensitive to imaging X-ray polarization fabricated by INAF/IAPS, INFN and OHB Italy. The focal length after boom deployment from ATK-Orbital is 4 m, while the spacecraft is being fabricated by Ball Aerospace. The sensitivity will be better than 5.5% in 300 ks for a 1E-11 erg/s/cm2 (half mCrab) in the energy band of 2-8 keV allowing for sensitive polarimetry of extended and point-like X-ray sources. The focal plane instrument is completed, calibrated and it is going to be delivered at MSFC. We will present the status of the mission at about one year from the launch.
Expected to launch in 2021 Spring, the Imaging X-ray Polarimetry Explorer (IXPE) is a NASA Astrophysics Small Explorer Mission with significant contributions from the Italian space agency (ASI). The IXPE observatory features three identical x-ray telescopes, each comprised of a 4-m-focal length mirror module assembly (MMA, provided by MSFC) that focuses x-rays onto a polarization-sensitive, imaging detector (contributed by ASI-funded institutions). This paper summarizes the MMA’s design, fabrication, alignment and assembly, expected performance, and calibration plans.
The Imaging X-ray Polarimetry Explorer (IXPE) will add polarization to the properties (time, energy, and position) observed in x-ray astronomy. A NASA Astrophysics Small Explorer (SMEX) in partnership with the Italian Space Agency (ASI), IXPE will measure the 2–8-keV polarization of a few dozen sources during the first 2 years following its 2021 launch. The IXPE Observatory includes three identical x-ray telescopes, each comprising a 4-m-focal-length (grazingincidence) mirror module assembly (MMA) and a polarization-sensitive (imaging) detector unit (DU), separated by a deployable optical bench. The Observatory’s Spacecraft provides typical subsystems (mechanical, structural, thermal, power, electrical, telecommunications, etc.), an attitude determination and control subsystem for 3-axis stabilized pointing, and a command and data handling subsystem communicating with the science instrument and the Spacecraft subsystems.
The Imaging X-ray Polarimetry Explorer (IXPE) will expand the information space for study of cosmic sources, by adding polarization to the properties (time, energy, and position) observed in x-ray astronomy. Selected in 2017 January as a NASA Astrophysics Small Explorer (SMEX) mission, IXPE will be launched into an equatorial orbit in 2021. The IXPE observatory includes three identical x-ray telescopes, each comprising a 4-m-focal-length (grazing-incidence) mirror module assembly (MMA) and a polarization-sensitive (imaging) detector unit (DU). The optical bench separating the MMAs from the DUs is a deployable boom with a tip/tilt/rotation stage for DU-to-MMA (gang) alignment, similar to the configuration used for the NuSTAR observatory. The IXPE mission will provide scientifically meaningful measurements of the x-ray polarization of a few dozen sources in the 2-8 keV band, over the first two years of the mission. For several bright, extended x-ray sources (pulsar wind nebulae, supernova remnants, and an active-galaxy jet), IXPE observations will produce polarization maps indicating the magnetic structure of the synchrotron emitting regions. For many bright pulsating x-ray sources (isolated pulsars, accreting x-ray pulsars, and magnetars), IXPE observations will produce phase-resolved profiles of the polarization degree and position angle.
The focusing performance of shell optics for the hard X-ray region strongly depends on their axial mid-spatialfrequency-
range figure errors. This paper presents the development of a deterministic computer-controlled polishing
process to minimize these axial figure errors on cylindrical shaped mandrels from which the mirror shells are replicated.
A mathematical model has been developed to simulate the residual surface figure errors due to the polishing process
parameters and the polishing tools used, along with their non-conformance to the mandrel. We present design
considerations of a large-size polishing lap where the experimentally determined process variables have been used for
optimizing the lap configuration and the machine operational parameters. Furthermore, the developed model is capable
of generating a corrective polishing sequence for a known surface error profile. Practical polishing experiments have
been performed to verify the model and to determine its ability to correct known axial figure errors through polishing
machine control.
The Constellation-X mission concept has been streamlined to a single Atlas V 551 configuration. This decision was reached by the project team after considering the increases in launch costs announced in 2006 coupled with the constrained budget environment apparent with the release of the NASA 2007 budget. Along with the Spectroscopy X-ray Telescopes, this new configuration continues to carry a Hard X-ray Telescope (HXT) component, with some modifications to the original requirements to adjust to the new configuration. The total effective area requirement in the 7 - 40 keV band has been reduced, but at the same time the angular resolution requirement has been increased from 1 arcmin to 30 arcsec. The Smithsonian Astrophysical Observatory, Marshall Space Flight Center and Brera Observatory (Italy) have been collaborating to develop and HXT which meets the requirements of Constellation-X. The development work we have been engaged in to produce multilayer coated Electroformed-Nickel-Replicate (ENR) shells is well suited for this new configuration. We report here on results of fabrication and testing of a prototyped optic for the HXT. Full beam illumination X-ray tests, taken at MPE-Panter Test Facility, show that these optics meet the new requirement of 30 arcsec for the streamlined Constellation-X configuration. This report also presents preliminary results from studies using titanium nitride as a release agent to simplify and improve the nickel electroforming replication process.
We are developing hard-x-ray optics using an electroformed-nickel-replication process off superpolished mandrels. To date, we have fabricated over 100 shells for our HERO balloon payload with typical angular resolutions in the 13-15 arcsec range. This paper discusses the factors currently limiting this resolution and various developments geared towards the production of higher-resolution optics.
The Constellation-X mission planned for launch in 2015-2020 timeframe, will feature an array of Hard X-ray telescopes (HXT) with a total collecting area greater than 1500 cm2 at 40 keV. Two technologies are being investigated for the optics of these telescopes, one of which is multilayer-coated Electroformed-Nickel-Replicated (ENR) shells. The attraction of the ENR process is that the resulting full-shell optics are inherently stable and offer the prospect of better angular resolution which results in lower background and higher instrument sensitivity. We are building a prototype HXT mirror module using an ENR process to fabricate the individual shells. This prototype consists of 5 shells with diameters ranging from 15 cm to 28 cm with a length of 42.6 cm. The innermost of these will be coated with iridium, while the remainder will be coated with graded d-spaced W/Si multilayers. The assembly structure has been completed and last year we reported on full beam illumination results from the first test shell mounted in this structure. We have now fabricated and coated two (15 cm and 23 cm diameter) 100 micron thick shells which have been aligned and mounted. This paper presents the results of full beam illumination X-ray tests, taken at MPE-Panter. The HEW of the individual shells will be discussed, in addition to results from the full two shell optic test.
We are developing grazing-incidence x-ray optics for a balloon-borne hard-x-ray telescope (HERO). The instrument will have 200 cm2 effective collecting area at 40 keV and an angular resolution goal of 15 arcsec. The HERO mirror shells are fabricated using electroformed-nickel replication off super-polished cylindrical mandrels. The angular resolution goal puts stringent requirements on the quality of the x-ray mirrors and, hence, on mandrel quality. We used metrology in an iterative approach to monitor and refine the x-ray mirror fabrication process. Comparison of axial slope measurements of the mandrel and the shells will be presented together with results from x-ray tests.
We are developing grazing incidence x-ray optics for a balloon-borne hard-x-ray telescope (HERO). The HERO mirror shells are fabricated using electroform-nickel replication off super-polished cylindrical mandrels. One of the sources for mirror resolution error is departure of the shell figure from prescription. We have modified a Vertical-scan Long Trace Profilometer (VLTP) in order to measure the figure of the inner surface of the HERO mirror shells for diameters as small as 74 mm. Metrology of the figure, the microroughness, tilt angle, the circularity for the shell mirrors and the mandrels, as well as alignment procedures are discussed. Comparison of metrology of the mandrel and the shells is presented together with results from x-ray tests.
The Constellation-X mission, planned for launch in 2013, will feature an array of hard-x-ray telescopes (HXT) with a total collecting area of greater than 1500 cm2 at 40 keV. Two technologies are currently being investigated for the optics of these telescopes including multilayer-coated Eletroformed-Nickel-Replicated (ENR) shells. The attraction of the ENR process is that the resulting full-shell optics are inherently stable and offer the prospect of better angular resolution which results in lower background and higher instrument sensitivity. The challenge for this process is to meet a relatively tight weight budget with a relatively dense material (ρnickel = 9 g/cm3.) To demonstrate the viability of the ENR process we are fabricating a prototype HXT mirror module to be tested against a competing segmented-glass-shell optic. The ENR prototype will consist of 5 shells of diameters from 150 mm to 280 mm with a length of 426 mm. To meet the stringent weight budget for Con-X, the shells will range in thickness from 100 microns to 150 microns. The innermost of these will be coated with Iridium, while the remainder will be coated with graded-dspaced W/Si multilayers. Mandrels for these shells are in the fabrication stage, the first test shells have been produced and are currently undergoing tests for figure and microroughness. A tentative date of June '04 has been set for the prototype X-ray testing at MSFC. Issues currently being addressed are the control of stresses in the multiplayer coating and ways of mitigating their effects on the figure of the necessarily thin shells. The fabrication, handling and mounting of these shells must be accomplished without inducing permanent figure distortions. A full status report on the prototype optic will be presented along with test results as available.
We have developed the electroformed-nickel replication process to enable us to fabricate light-weight, high-quality mirrors for the hard-x-ray region. Two projects currently utilizing this technology are the production of 240 mirror shells, of diameters ranging from 50 to 94 mm, for our HERO balloon payload, and 150- and 230-mm-diameter shells for a prototype Constellation-X hard-x-ray telescope module. The challenge for the former is to fabricate, mount, align and fly a large number of high-resolution mirrors within the constraints of a modest budget. For the latter, the challenge is to maintain high angular resolution despite weight-budget-driven mirror shell thicknesses (100 μm) which make the shells extremely sensitive to fabrication and handling stresses, and to ensure that the replication process does not degrade the ultra-smooth surface finish (~3Å) required for eventual multilayer coatings. We present a progress report on these two programs.
We are fabricating optics for the hard-x-ray region using electroform nickel replication. The attraction of this process, which has been widely used elsewhere, is that the resulting full shell optics are inherently stable and thus can have very good angular resolution. The challenge with this process is to develop lightweight optics, and to keep down the costs of mandrel fabrication. We accomplished the former through the development of high-strength, low-stress nickel alloys that permit very thin, stable, shells without fabrication- and handling-induced deformations. For the latter, we have utilized inexpensive grinding and diamond turning to figure the mandrels and then purpose-built polishing machines to finish the surface. In-house plating tanks and a simple water-bath separation system complete the process. To date we have built shells ranging in size from 5 cm diameter to 50 cm, and with thickness down to 100 micron. For our HERO balloon program, we are fabricating over 200 iridium-coated shells, 250 microns thick, for hard-x-ray imaging up to 75 keV. Early test results on these have indicated half-power-diameters of 15 arcsec. The status of these developments will be reviewed.
HERO is a balloon payload featuring shallow-graze angle replicated optics for hard-x-ray imaging. When completed, the instrument will offer unprecedented sensitivity in the hard-x-ray region, giving thousands of sources to choose from for detailed study on long flights. A recent proof-of-concept flight captured the first hard-x-ray focused images of the Crab Nebula, Cygnus X-1 and GRS 1915+105. Full details of the HERO program are presented, including the design and performance of the optics, the detectors and the gondola. Results from the recent proving flight are discussed together with expected future performance when the full science payload is completed.
We are developing high-energy grazing-incidence optics for a balloon-borne hard-x-ray telescope. When completed the instrument, termed HERO for High Energy Replicated Optics, will have 200 cm2 effective collecting area at 40 keV and <EQ 30 arcsec angular resolution. The payload will offer unprecedented sensitivity in the hard-x-ray region, with milliCrab level sensitivity on a one-day balloon flight and 100 microCrab on an ultra-long-duration flight. While the full science payload is scheduled for flight in 2002, an engineering/proving flight is currently awaiting launch. This flight, consisting of just two mirror modules, each containing three nested shells above a pair of gas scintillation proportional counter focal plane detectors, is intended to test a newly designed gondola pointing and aspect system and to examine the stability of optical bench designs. This paper provides an overview of the HERO program.
We are developing high-energy replicated optics for a balloon-borne hard-x-ray telescope. When completed, the telescope will have around 130 cm2 of effective collecting area at 60 keV, and an angular resolution of <EQ 30 arc seconds, half power diameter. With an array of gas scintillation proportional counters in the focal plane the payload will provide unprecedented sensitivity for pointed observations in the hard-x-ray band. We present an overview of the HERO program, together with test data from the first mirror shell. The overall sensitivity of the full payload is given for planned long- and ultra-long-duration balloon flights.
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