Additive manufacturing (AM; 3D printing) in aluminium using laser powder bed fusion provides a new design space for lightweight mirror production. Printing layer-by-layer enables the use of intricate lattices for mass reduction, as well as organic shapes generated by topology optimisation, resulting in mirrors optimised for function as opposed to subtractive machining. However, porosity, a common AM defect, is present in printed aluminium and it is a result of the printing environment being either too hot or too cold, or gas entrapped bubbles within the aluminium powder. When present in an AM mirror substrates, porosity manifests as pits on the reflective surface, which increases micro-roughness and therefore scattered light. There are different strategies to reduce the impact of porosity: elimination during printing, coating the aluminium print in nickel phosphorous, or to apply a heat and pressure treatment to close the pores, commonly known as a hot isostatic press (HIP).
This paper explores the application of HIP on printed aluminium substrates intended for mirror production using single point diamond turning (SPDT). The objective of the HIP is to reduce porosity whilst targeting a small grain growth within the aluminium, which is important in allowing the SPDT to generate surfaces with low micro-roughness. For this study, three disks, 50 mm diameter by 5 mm, were printed in AlSi10Mg at 0◦, 45◦, and 90◦ with respect to the build plate. X-ray computed tomography (XCT) was conducted before and after the HIP cycle to confirm the effectiveness of HIP to close porosity. The disks were SPDT and the micro-roughness evaluated. Mechanical testing and electron backscatter diffraction (EBSD) was used to quantify the mechanical strength and the grain size after HIP.
Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.
KEYWORDS: Prototyping, Design and modelling, Single point diamond turning, Optical surfaces, Porosity, Simulations, Mirrors, Mirror surfaces, 3D printing, Additive manufacturing
Additive manufacturing (AM; 3D Printing) is a process that fabricates objects layer-by-layer, unlocking previously unachievable geometrical freedom in design and manufacture. Its adoption for the manufacture of optical components for nanosats is challenging due to limited understanding of its inherent porosity and outgassing properties; however, AM has plenty of potential for lightweight space-based mirror structures as it enables the use of lattice structures and topology optimisation. AM is particularly relevant to nanosat deployable optics (DO) instrumentation, where a segmented mirror needs to be packed within a limited volume and mass budget. This paper describes the design, analysis, manufacture and metrology of AM mirror petal prototypes for a 6U nanosat DO payload. The objective of the prototypes was to reduce the mass and the part count relative to the conventional design. From the available 33 volumetric lattices including graph, triply periodic minimal surface and stochastic lattices within the AM design software used, two were downselected by using finite element analysis and manufacturability experiments. Prototypes were designed using these lattices, and the geometric and interface requirements of the conventional petal. These were printed, using laser powder bed fusion, in the aluminium alloy AlSi10Mg and post-processed using single point diamond turning. The internal (porosity) and external geometrical properties of the manufactured prototypes were measured using X-ray computed tomography and the optical properties of the reflective surface evaluated using interferometry. By utilising AM, a mass reduction of 44 % and the consolidation of nine parts into one was achieved.
Details of a programme to investigate the outgassing rate of additively manufactured (AM) aluminium alloys are presented. AM has significant potential benefits to applications in ground- and space-based instrumentation, particularly in mass optimisation, part consolidation and increased design freedom. However, its use in high-risk projects is often curtailed by lack of heritage and an imperfect understanding of the materials. The programme goal was to address one of the most significant topics preventing wider adoption of AM technology in cryogenic and space-based applications; uncertainty about material outgassing. The sensitivity of outgassing rates to various key parameters was characterised, including print method, post-processing and geometrical complexity. Correlation of outgassing rates against other measurable properties, such as sample porosity and surface roughness, was also investigated via the use of X-ray computed tomography and profilometry. Finally, the test apparatus, experimental design and implications of the findings on design and process control are discussed.
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