Aluminum metal matrix composites: a capable low-cost mirror substrate

Alex Few; Jason Echols

doi:10.1117/12.2677689

4 October 2023 Aluminum metal matrix composites: a capable low-cost mirror substrate

Alex Few, Jason Echols

Proceedings Volume 12677, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems IV; 1267705 (2023) https://doi.org/10.1117/12.2677689
Event: SPIE Optical Engineering + Applications, 2023, San Diego, California, United States

Abstract

Outpost Technologies designed, manufactured, and tested a 0.305-meter aluminum-silicon carbide metal matrix composite (Al-SiC MMC) mirror for infrared balloon gondola observatory application. Al-SiC MMCs, such as Materion’s SupremEX®, have high specific stiffness, excellent thermal conductivity, and lower CTE than most conventional metals. Furthermore, recent research and development efforts support a brand-new material for investigation: AyontEX™ 13 aluminum-silicon (Al-Si) alloy. Outpost identified significant cost and capability gaps in mirror substrate design trades between ultra-premium beryllium and SiC and conventional aerospace materials and proposes new materials for consideration. The Al-SiC MMC and Al-Si alloy programmatic and technical value proposition combines considerable improvements in specific stiffness and thermal performance at minimal costs increases over aluminum substrates. Assuming congruent geometry, SupremEX® 640XA Al-SiC MMCs reduce gravity sag errors by 47% and increases mirror and structural modes by 35% versus aluminum 5000 and 6000 series without affecting system mass. AyontEX™ 13 also exhibits higher specific strength and stiffness compared to aluminum and shows promise as an uncoated mirror substrate with optical surface finish properties achieved during diamond turning. Outpost presents study results, manufacturability assessments, and ground test concepts for TRL-advancing activities to bring the SupremEX® and AyontEXTM materials before future optics programs as highly capable and low-cost mirror substrates. Lastly, a discussion of ongoing and future work for ultraviolet (UV) and large (> 1.25-meter) Al-SiC MMC and Al-Si alloy applications.

Conference Presentation

(2023) Published by SPIE. Downloading of the abstract is permitted for personal use only.

Citation Download Citation

Alex Few and Jason Echols "Aluminum metal matrix composites: a capable low-cost mirror substrate", Proc. SPIE 12677, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems IV, 1267705 (4 October 2023); https://doi.org/10.1117/12.2677689

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