Despite thorough and careful surface cleaning, evaporated or sputtered metallic aluminum mirror coatings are well known to be plagued by a multitude of pinholes in the coatings. These pinholes contribute to light scattering and light reduction. Subsequent corrosion and penetration of contaminants in the pinholes and on the edges of the metal coating result in degradation and eventual coating destruction. At this point, mirrors are stripped, cleaned, and recoated with aluminum. In this work, we report the reduction of coating pinholes by up to a factor of 100x by utilizing First Contact Polymer Apply-Dry Peel technology as a final step in surface cleaning before coating.
We fabricated an intensity-controlled imaging system to image backside illuminated optics and quantify the pinholes in aluminum mirror films. Imagej analysis of the size-calibrated pinhole distribution and light intensity resulted in statistical distributions plots of intensity vs pinhole size for each sample. Samples were prepared by stripping existing coatings with Green River mirror strip solution, followed by a standard cleaning procedure that consisted of a light NaOH wash, hand polishing with calcium carbonate slurry, alconox solution wash, distilled water(2X), and 200 proof ethanol wash (2x). After drying, one substrate was placed in the vacuum chamber and sputter coated with aluminum. The other sample was coated with Red First Contact Polymer Solution, allowed to dry, and the polymer film peeled of after pacing the substrate in the chamber for coating. Results show that the conventionally treated cleaned and dragwiped surfaces had 758 and 435 pinholes and the polymer strip coating cleaned surfaces had 38 and 9 pinholes. We believe that further studies and modified surface pretreatments can pave the way to reliably make zero defect coatings, not just for aluminum mirrors, but for all optical coatings.
First Contact (FC) Polymer™, developed by Photonic Cleaning Technologies, is used to clean and protect surfaces from contamination. The polymer creates a peelable coating that renders the surface clean while not leaving visible residues. To investigate the effectiveness of FC at the subnanometer level, we used variable-angle, spectroscopic ellipsometry (VASE) to measure sample top-layer thickness after repeated application/storage/removal cycles of standard (red) FC with three sample sets (CVD Si3N4 on Si, bare Si, and SiO2 on Si). The samples were measured via VASE after every FC removal to understand contaminant thickness changes with “peel-off” count. Control samples were also measured at each iteration. Ellipsometric analysis revealed FC removed, during the first peel-off, impurity from the surface of samples treated with impure isopropyl alcohol. Linear regressions and t-tests comparing samples with and without FC were employed for evaluating changes with peel-off counts. There is evidence for the very slight build-up of material which is not removed by iterative FC application/removal cycles on these samples. It is slight, <0.1 nm after 17 iterations, in the case of native oxide on Si.
NASA's Exo-S Starshade Mission plans to spectroscopically characterize exo-Earths orbiting stars in their "Goldilocks Zone" using an occulter (the "Starshade") to suppress starlight by 10^10. LUVOIR, HabEx and other missions may also depend on starshades. Other missions, such as LISA, critically depend on complete elimination of light scatter, as does the terrestrial LIGO. We report data on a family of novel, peelable, low-adhesion, residueless polymer coatings to clean and protect Starshade edges and other surfaces of importance to NASA, with uses ranging from fabrication to integration and testing to launch.
First Contact Polymers from Photonic Cleaning Technologies have been used on many world-class telescopes for protection and for cleaning to maintain reflectivity to "as new" condition. W.M. Keck, Space Surveillance Telescope, MCAT Ascension Island, ESO, CFHT, LIGO, and others have all used First Contact to clean mirrors and optics to the molecular level.
Many optical surfaces such as space and telescope mirrors are historically "uncleanable" and extraordinary measures are utilized to remove, recoat and therefore subsequently realign astronomical telescope systems resulting in extensive downtimes. Others, such as those used in space systems are extremely sensitive to organic contamination and particulate and residue removal is critical to performance. In this paper we present some recent data and examples that the strip coating First Contact Polymer, resulting from R&D from our labs, restores astronomical mirrors to like new condition by cleaning in situ and provides superior cleaning & protection from recontamination for telescopes, space instruments and other technologically important surfaces. We will also present data that these polymeric systems clean to the atomic level and that Laser Induced Damage (LIDT) results indicate that it leaves no residue. We will present details and supporting evidence that that our polymers, that were a critical enabling technology in LIGO’s Gravity wave discoveries of 2016, can greatly extend the lifetime of current mirror coatings on large astronomical mirrors.
While many materials could be used as IR mirrors, only aluminum has the potential of reaching far into the ultraviolet, as low as 85 nm. Unfortunately, Al oxidizes rapidly when it is exposed to the atmosphere, diminishing the reflectance of bare aluminum mirrors below 200 nm. For terrestrial observations, this is not a large problem, since the Earth’s atmosphere blocks radiation below this wavelength. However, mirrors used in space could use the whole range of aluminum’s reflectance, if a bare, or nearly bare mirror, could be deployed.[1] The compromise to date has been to use a thin UV-transparent, protective barrier composed of magnesium fluoride, lithium fluoride and/or aluminum fluoride. These allow the observation of the Lyman alpha line but light below 110 nm is effectively blocked. We report on our studies of ultrathin fluoride barrier layers and of removable layers which would lie on ultrathin fluoride barriers or directly on the aluminum surface. Removable barriers could be removed shortly before launch or at the mirrors point of use. These removable barriers consist of organic layers like First Contact™ or parylene, inorganic layers like amorphous silicon (a-Si), or a combination of both. We have observed, for example, that ultrathin films of AlF3 (<2.5 nm) are capable of blocking the oxidation of aluminum for several hours in air, long enough to have a removable barrier like First Contact™ applied on their surface. We also report on the effectiveness of ultrathin a-Si as a long-term barrier that may be removable via atomic hydrogen.
Statistically based Laser Damage Testing (LDT) was performed on clean, polished silicon wafers before and
after First Contact Polymer was applied and removed. Polymer removal results in surfaces that are nearly
atomically clean as evidenced by XPS data and may be a starting basis for developing an LDT based surface
cleanliness test. A LabView controlled nanosecond YAG based LDT system with motion control stages
was built and used to demonstrate significant difference in surface laser damage threshold following cleaning
of already "clean" surfaces. These initial results represent the beginning of a systematic study on a variety of
surfaces to include glass, silicon, germanium, coatings and nonlinear optical crystals as well as diffraction
gratings. Recent independent testing lab results demonstrate YAG laser damage thresholds after polymer removal,
indistinguishable from that of new high power laser optics, on coated BK7 of 15J/cm2 at 20ns and
20Hz. Our initial data indicate a significant increase, as much as 10% in LDT post cleaning.
We describe the results obtained cleaning the surface of DECam CCD detectors with a new electrostatic dissipative
formulation of First ContactTM polymer from Photonic Cleaning Technologies. We demonstrate that
cleaning with this new product is possible without ESD damage to the sensors and without degradation of the
antireflective coating used to optimize the optical performance of the detector. We show that First ContactTM
is more effective for cleaning a CCD than the commonly used acetone swab.
Cleaning mirrors for coating is a very exacting process and for larger mirrors it can be physically demanding. The final
step of cleaning and drying the substrate is particularly problematic. Non-contact drying methods, usually with
compressed air or nitrogen, can be laborious and can introduce contaminants if the compressed gas used is insufficiently
pure. These methods also tend to increase the static charge on the substrate surface, attracting lint. Contact methods
tend to add lint or fibers to the cleaned surface. As an alternative, we are experimenting with using the First Contact
polymer cleaning solution as the final step in mirror coating preparation. The advantage of this method is that the
polymer coating, which will adhere to much of the remaining surface contaminants, may be left on the substrate until
just before it is placed into the coating chamber, minimizing the time available for re-contamination. The results of our
experiments on small substrates are presented.
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