The James Webb Space Telescope’s (JWST) center of curvature optical bench (CoCOB) hexapod was repurposed to enhance NASA Marshall Space Flight Center’s X-Ray & Cryogenic Facility (XRCF) optical metrology capabilities. This upgrade unlocked higher test article load capacity and extended the allowable ranges of motion of the CoCOB hexapod. The hexapod was also coupled to a new long-stroke, linear motion axis to form a 7 degrees of freedom system and allow for high precision testing of larger diameter test articles. A 9 degrees of freedom motion system, consisting of a three-axis linear mount in an X-Y-Z configuration and a commercially available hexapod, was also designed to allow high resolution positioning of the focal plane instrumentation over a large range of motion. A modern control architecture and graphical user interface was developed for the CoCOB hexapod and additional motion stages to permit streamlined commanding and operation. This paper discusses the justification for re-using the CoCOB hexapod by highlighting its unique precision motion control capabilities in a high vacuum and optically clean environment. The design, key component selection, and environmental compatibility for each of the additional motion stages is presented along with testing results for achieved range, repeatability, and minimum step size performance for all motion axes. Finally, a summary of the motion control system architecture and its flexibility to address tomorrow’s optical metrology needs are presented.
NASA / MSFC has been preparing for X-ray calibration of the large
optic for the future ESA Athena mission at the 500 meter XRCF
beamline. Improvements include new facility X-ray detectors (Six
Amptek C2 window SDDs and a PI-MTE3 4k CCD camera), stages, and
verification of the facility's operation to the level reached for the
ground calibration of the Chandra X-ray telescope. The XRCF 1.5
meter beam size requires that a flight Athena optic be calibrated by
combining measurements from the six individual sub-sectors of the full
optic. New XRCF capabilities for the Athena measurement include the
ability to measure 12 meter focal length optics with the focal point
not co-linear with the facility optical axis.
As part of these preparations, in January 2023 we tested an SPO module
at the XRCF, aligning the optic in the facility and measuring the
point spread function and effective area at two separate energies.
Our results agree well with previous measurements of this module taken
at the MPE PANTER X-ray beamline. We present a synopsis of the
XRCF facility and its X-ray testing equipment, results from the
XRT#4 testing campaign in January 2023, and show that the XRCF is
currently capable of testing and calibrating large optics for the next
generation of flagship and probe class X-ray observatories.
The X-Ray and Cryogenic Facility (XRCF) at Marshall Space Flight Center is the world’s largest x-ray optic calibration facility and NASA’s premier cryogenic optical test facility. Built specifically to calibrate the Chandra telescope, the facility contributed to several other x-ray missions until 2005 when it became dedicated to normal incidence optical testing at cryogenic temperatures. Recently the facility’s x-ray test capability has been returned to service and updated. New beam monitors, focal plane detectors, and test article and instrument positioning systems have been added. The x-ray data acquisition system has been updated. A real-time position monitoring metrology system is being developed that will enable calibration of large diameter optics via partial illumination in a diverging beam. The newly expanded x-ray test capabilities of the facility will be discussed.
The x-ray and cryogenic facility is the baseline x-ray performance verification and calibration facility for the mirror demonstrator (MAMD), the qualification module (QM), and the flight module (FM) of the ATHENA ESA L-class mission. The ATHENA mirror will be the largest x-ray optic ever built, and due to its size and segmented nature it can only be partially illuminated during testing and calibration. Here we explore what this means for the method and procedure to align the mirror and obtain the effective area, point spread function, and focal length at the XRCF with raytracing and simulation. We will discuss the effects of gravity on such a large and heavy mirror, and investigate the challenge of stitching results together from different sectors due to sub-aperture illumination.
The X-ray and Cryogenic Facility (XRCF) at the NASA Marshall Space
Flight Center (MSFC) is the baselined facility for X-ray testing of
the Athena X-ray optics. Here we give an overview of the planned
testing, including the XRCF facility and its 500-meter X-ray
beamline, the required facility X-ray sources and detectors,
testing requirements, and the GSE required for X-ray testing and
calibration of the Athena mirror assembly module demonstrator (MAMD),
the qualification model mirror (QM), and the flight model mirror (FM).
Of special interest is the metrology system needed for the
calibration: because the large Athena optic (the Mirror Assembly
Module, or MAM) is too large for full illumination in the XRCF 1.5m
diameter X-ray beam, the six sectors of the MAM will be tested
separately, requiring precise knowledge of the optic and detector
positions during the calibration to enable the stitching together of
the full MAM point spread function from measurements of the individual
sectors.
2014 marks the crystal (15th) anniversary of the launch of the Chandra X-ray Observatory, which began its existence as the Advanced X-ray Astrophysics Facility (AXAF). This paper offers some of the major lessons learned by some of the key members of the Chandra Telescope team. We offer some of the lessons gleaned from our experiences developing, designing, building and testing the telescope and its subsystems, with 15 years of hindsight. Among the topics to be discussed are the early developmental tests, known as VETA-I and VETA-II, requirements derivation, the impact of late requirements and reflection on the conservatism in the design process.
Ron Eng, William Arnold, Markus Baker, Ryan Bevan, Gregory Burdick, Michael Effinger, Darrell Gaddy, Brian Goode, Craig Hanson, William Hogue, Jeffrey Kegley, Charlie Kirk, Steven Maffett, Gary Matthews, Richard Siler, W. Scott Smith, H. Philip Stahl, John Tucker, Ernest Wright
A 43cm diameter stacked core mirror demonstrator was interferometrically tested at room temperature down to 250 degrees Kelvin for thermal deformation. The 2.5m radius of curvature spherical mirror assembly was constructed by low temperature fusing three abrasive waterjet core sections between two CNC pocket milled face sheets. The 93% lightweighted Corning ULE® mirror assembly represents the current state of the art for future UV, optical, near IR space telescopes. During the multiple thermal test cycles, test results of interferometric test, thermal IR images of the front face were recorded in order to validate thermal optical model.
KEYWORDS: Curium, James Webb Space Telescope, Cryogenics, Composites, Temperature metrology, Space telescopes, Mirrors, Manufacturing, Metrology, Analytical research
The need for JWST's metering structure to be stable over time while at cryogenic temperatures is derived from its
scientific objectives. The operational scenario planned for JWST provides for the optical system to be adjusted on
regular intervals based upon image quality measurements. There can only be a limited amount of optical
degradation between the optical system adjustments in order to meet the scientific objectives. As the JWST primary
mirror is segmented, the structure supporting the mirror segments must be very stable to preclude degradation of the
optical quality. The design, development and, ultimately, the verification of that supporting structure's stability rely
on the availability of analysis tools that are credibly capable of accurately estimating the response of a large
structure in cryogenic environments to the nanometer level. Validating the accuracy of the analysis tools was a
significant technology demonstration accomplishment. As the culmination of a series of development efforts, a
thermal stability test was performed on the Backplane Stability Test Article (BSTA), demonstrating TRL-6 status
for the design, analysis, and testing of Large Precision Cryogenic Structures. This paper describes the incremental
development efforts and the test results that were generated as part of the BSTA testing and the associated TRL-6
demonstration.
Marshall Space Flight Center's X-ray Cryogenic Facility (XRCF) has been performing optical wavefront testing and
thermal structural deformation testing at sub-liquid nitrogen cryogenic temperatures since 1999. Recent modifications
have been made to the facility in support of the James Webb Space Telescope (JWST) program. The test article
envelope and the chamber's refrigeration capacity have both been increased. A new larger helium-cooled enclosure has
been added to the existing enclosure increasing both the cross-sectional area and the length. This new enclosure is
capable of supporting six JWST Primary Mirror Segment Assemblies. A second helium refrigeration system has been
installed essentially doubling the cooling capacity available at the facility. Modifications have also been made to the
optical instrumentation area. Improved access is now available for both the installation and operation of optical
instrumentation outside the vacuum chamber. Chamber configuration, specifications, and performance data will be
presented.
KEYWORDS: Distortion, James Webb Space Telescope, Manufacturing, Magnetism, Temperature metrology, Composites, 3D modeling, Aluminum, Space telescopes, Metrology
The unprecedented stability requirements of JWST structures can only be conclusively
verified by a combination of analysis and ground test. Given the order of magnitude of the
expected motions of the backplane due to thermal distortion and the high level of confidence
required on such a large and important project, the demonstration of the ability to verify the
thermal distortion analysis to the levels required is a critical need for the program. The
demonstration of these analysis tools, in process metrology and manufacturing processes
increases the technology readiness level of the backplane to required levels. To develop this
critical technology, the Backplane Stability Test Article (BSTA) was added to the JWST
program. The BSTA is a representative substructure for the full flight backplane, manufactured
using the same resources, materials and processes. The BSTA will be subject to environmental
testing and its deformation and damping properties measured. The thermally induced
deformation will be compared with predicted deformations to demonstrate the ability to predict
thermal deformation to the levels required. This paper will review the key features and
requirements of the BSTA and its analysis, the test, measurement and data collection plans.
Low cost, high performance lightweight Silicon Carbide (SiC) mirrors provide an alternative to Beryllium mirrors. A Trex Enterprises 0.25m diameter low areal density SiC mirror using its patented Chemical Vapor Composites (CVC) technology was evaluated for its optical performance at cryogenic temperature. CVC SiC is chemically pure, thermally stable, and mechanically stiff. CVC technology yields higher growth rate than that of CVD SiC. NASA has funded lightweight optical materials technology development efforts for future space based telescope programs. As part of these efforts, a Trex SiC mirror was measured interferometrically from room temperature to 30 degrees Kelvin. This paper will discuss the test goals, the cryogenic optical testing infrastructure and instrumentation at MSFC, test results, and lessons learned.
Schafer has demonstrated two different methods for actively cooling our Silicon Lightweight Mirror System (SLMSTM) technology. Direct internal cooling was accomplished by flowing liquid nitrogen through the continuous open cell core of the SLMSTM mirror. Indirect external cooling was accomplished by flowing liquid nitrogen through a CTE matched Cesic® square-tube manifold that was bonded to the back of the mirror in the center. Testing was done in the small 4-
foot thermal/vacuum chamber located at the NASA/MSFC X-Ray Calibration Facility. Seven thermal diodes were located over the front side of the 5 inch diameter mirror and one was placed on the outlet side of the Cesic® manifold. Results indicate that the mirror reaches steady state at 82K in less than four minutes for both cooling methods. The maximum temperature difference of the eight diodes was less than 200 mK when the mirror was internally cooled and covered with MLI to insulate it from the large 300 K aluminum plate that was used to mount it.
The technology associated with the use of silicon carbide (SiC) for high-performance mirrors has matured significantly over the past 10-20 years. More recently, the material has been considered for cryogenic applications such as space-based infrared telescopes. In light of this, NASA has funded several technology development efforts involving SiC mirrors. As part of these efforts, three lightweight SiC mirrors have been optically tested at cryogenic temperatures within the X-Ray Calibration Facility (XRCF) at Marshall Space Flight Center (MSFC). The three mirrors consisted of a 0.50 m diameter carbon fiber-reinforced SiC, or C/SiC, mirror from IABG in Germany, a 0.51 m diameter SiC mirror from Xinetics, Inc., and a 0.25 m diameter SiC mirror from POCO Graphite, Inc. The surface figure error was measured interferometrically from room temperature (~290 K) to ~30 K for each mirror. The radius-of-curvature (RoC) was also measured over this range for the IABG C/SiC & Xinetics SiC mirrors. This paper will describe the test goals, the test instrumentation, and the test results for these cryogenic tests.
SLMS athermal technology has been demonstrated in the small 4-foot helium cryogenic test chamber located at the NASA/MSFC X-Ray Calibration Facility (XRCF). A SLMS Ultraviolet Demonstrator Mirror (UVDM) produced by Schafer under a NASA/MSFC Phase I SBIR was helium cryo tested both free standing and bonded to a Schafer designed prototype carbon fiber reinforced silicon carbide (Cesic) mount. Surface figure data was obtained with a test measurement system that featured an Instantaneous Phase Interferometer (IPI) by ADE Phase Shift. The test measurement system's minimum resolvable differential figure deformation and possible contributions from test chamber ambient to cryo window deformation are under investigation. The free standing results showed differential figure deformation of 10.4 nm rms from 295K to 27K and 3.9 nm rms after one cryo cycle. The surface figure of the UVDM degraded by lambda/70 rms HeNe once it was bonded to the prototype Cesic mount. The change was due to a small astigmatic aberration in the prototype Cesic mount due to lack of finish machining and not the bonding technique. This effect was seen in SLMS optical assembly results, which showed differential figure deformation of 46.5 nm rms from 294K to 27K, 42.9 nm rms from 294K to 77K, 28.0 nm rms from 294K to 193K and 6.2 nm rms after one cryo cycle.
Marshall Space Flight Center (MSFC) has been performing optical wavefront testing at cryogenic temperatures since 1999 in the Space Optics Manufacturing Technology Center's (SOMTC's) X-ray / Cryogenic Facility (XRCF). Recently the cryogenic optical testing capability has been extended to a smaller chamber. This smaller horizontal cylindrical vacuum chamber has been outfitted with a helium-cooled liner that can be connected to the existing helium refrigeration system bringing the kilowatt of refrigeration capacity to bear on a 1 x 2 meter test envelope. Cryogenic cycles to 20 Kelvin, including set-up and chamber evacuation/backfill, are now possible in only a few days. Since activation and chamber characterization tests in September 2001, the new chamber has been used to perform a number of proprietary cryogenic tests on mirrors, adhesives, and actuators. A vibration survey has also been performed on the test chamber. Chamber specifications and performance data, vibration environment data, and optical test capability will be discussed.
An Optical Testing System (OTS) has been developed to measure the figure and radius of curvature of Next Generation Space Telescope (NGST) developmental mirrors in a vacuum, cryogenic environment using the X-Ray Calibration Facility (XRCF) at Marshall Space Flight Center (MSFC). The OTS consists of a WaveScope Shack-Hartmann sensor from Adaptive Optics Associates as the main instrument and a Leica Disto Pro distance measurement instrument. Testing is done at the center of curvature of the test mirror and at a wavelength of 632.8 nm. The error in the figure measurement is <EQ(lambda) /13 peak-to-valley (PV). The error in radius of curvature is less than 5 mm. The OTS has been used to test the Subscale Beryllium Mirror Demonstrator (SBMD), a 0.532-m diameter spherical mirror with a radius of curvature of 20 m. SBMD characterization consisted of three separate cryogenic tests at or near 35 K. The first two determined the cryogenic changes in the mirror surface and their repeatability. The last followed cryo-figuring of the mirror. This paper will describe the results of these tests. Figure results will include full aperture results as well as an analysis of the mid-spatial frequency error results. The results indicate that the SBMD performed well in these tests with respect to the requirements of (lambda) /4 PV (full aperture), (lambda) /10 PV (mid-spatial, 1-10 cm), and +/- 0.1 m for radius of curvature after cryo-figuring.
The successful augmentation of NASA's X-Ray Cryogenic Facility (XRCF) at the Marshall Space Flight Center (MSFC) to an optical metrology testing facility for the Sub-scale Beryllium Mirror Development (SBMD) and NGST Mirror Sub-scale Development (NMSD) programs required significant modifications and enhancements to achieve useful and meaningful data. In addition to building and integrating both a helium shroud and a rugged and stable platform to support a custom sensor suite, the sensor suite was assembled and integrated to meet the performance requirements for the program. The subsequent evolution from NMSD and SBMD testing to the Advanced Mirror System Demonstrator (AMSD) program is less dramatic in some ways, such as the reutilization of the existing helium shroud and sensor support structure. However, significant modifications were required to meet the AMSD program's more stringent test requirements and conditions resulting in a substantial overhaul of the sensor suite and test plan. This overview paper will discuss the instrumentation changes made for AMSD, including the interferometer selection, null optics, and radius of curvature measurement method. The error budgeting process will be presented, and the overall test plan developed to successfully carry out the tests will be discussed.
NASA Marshall Space Flight Center has maintained and operated a world-class x-ray optics and detector testing facility known as the X-ray Calibration Facility (XRCF) since the mid 1970's. The ground testing and calibration of the Chandra X-ray Observatory optics and detectors were successfully completed at the XRCF in 1997. In 1999, the facility was upgraded in preparation for cryogenic testing of lightweight telescope mirrors without compromising the existing x-ray testing capability. A gaseous Helium cooled enclosure or shroud capable of 20 degrees Kelvin and vibration isolated instrumentation mount were added to the existing facility. A precision remote-control five-axis motion mirror support was modified to operate under cryogenic conditions. Mirrors with diameters as large as two meters, and radii of curvature up to twenty meters can be accommodated in the He shroud.
Jonathan Barnes, Peter Roming, J. Moody, R. Steven Turley, Paul Eastman, T. Lloyd, K. Eldredge, Allen Raines, J. Cary Reily, Jeffrey Kegley, John Keidel, Jeff McCracken, Kenneth Whitley, Ernest Wright, Markus Baker, James Carpenter, D. Chavers, Harlan Haight, K. Barry Hale, Thomas Hill, David Javins, Joseph Norwood, Richard Siler, John Tucker, David Watson, R. Takahashi
The GoldHelox Solar X-ray Telescope underwent several tests during the years of 1997 - 1999, and continues through the testing phase of the project. The instrument itself, a solar telescope to ride on board the Space Shuttle, is designed to photograph the sun in soft x-ray wavelengths between 171 angstroms to 181 angstroms. Critical to its success, many tests are required to insure safety, robustness, and overall accuracy of the telescope during its mission. Among these are shake table tests, optical tests, vacuum integrity, and thermal analysis. This paper describes the GoldHelox project including its current status as a mission, the tests performed on the instrument to date, and the tests pending.
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