Francesco Martelli

Accurate integration of segmented x-ray optics using interfacing ribs

Abstract. Future lightweight and long-focal-length x-ray telescopes must guarantee a good angular resolution (e.g., 5 arc sec HEW) and reach an unprecedented large effective area. This goal can be reached with the slumping of borosilicate glass sheets that allow the fabrication of lightweight and low-cost x-ray optical units (XOU). These XOUs, based on mirror segments, have to be assembled together to form complete multishell Wolter-I optics. The technology for the fabrication and the integration of these XOUs is under development in Europe, funded by European Space Agency, and led by the Brera Observatory (INAF-OAB). While the achievement of the required surface accuracy on the glass segments by means of a hot slumping technique is a challenging aspect, adequate attention must be given to the correct integration and coalignment of the mirror segments into the XOUs. To this aim, an innovative assembly concept has been investigated, based on glass reinforcing ribs. The ribs connect pairs of consecutive foils, stacked into a XOU, with both structural and functional roles, providing robust monolithic stacks of mirror plates. Moreover, this integration concept allows the correction of residual low-frequency errors still present on the mirror foil profile after slumping. We present the integration concept, the related error budget, and the results achieved so far with a semi-robotic integration machine especially designed and realized to assemble slumped glass foils into XOUs.

Cold-shaping of thin glass foils as a method for mirror processing: from basic concepts to mass production of mirrors

Abstract. We present a method for the production of segmented optics. It is a process developed at INAF-Osservatorio Astronomico di Brera (INAF-OAB) employing commercial of-the-shelf materials. It is based on the shaping of thin glass foils by means of forced bending that occurs at room temperature [cold-shaping (CS)]. The glass is then assembled into a sandwich structure for retaining the imposed shape. The principal mechanical features of the mirrors are their low weight, rigidity and environmental robustness. The cost and production time also are competitive. We sum up the results achieved during research and development performed in the past years. We have investigated the theoretical limits of the structural components by means of parametric finite elements analyses; we also discuss the effects caused by the most common structural loads. Finally, the process implementation, the more significant validation tests and the mass production at the industry are described.

X-ray optics developments at ESA

Future high energy astrophysics missions will require high performance novel X-ray optics to explore the Universe beyond the limits of the currently operating Chandra and Newton observatories. Innovative optics technologies are therefore being developed and matured by the European Space Agency (ESA) in collaboration with research institutions and industry, enabling leading-edge future science missions. Silicon Pore Optics (SPO) [1 to 21] and Slumped Glass Optics (SGO) [22 to 29] are lightweight high performance X-ray optics technologies being developed in Europe, driven by applications in observatory class high energy astrophysics missions, aiming at angular resolutions of 5” and providing effective areas of one or more square meters at a few keV. This paper reports on the development activities led by ESA, and the status of the SPO and SGO technologies, including progress on high performance multilayer reflective coatings [30 to 35]. In addition, the progress with the X-ray test facilities and associated beam-lines is discussed [36].

Design of the IXO optics based on thin glass plates connected by reinforcing ribs

Effective area requirements for the large X-ray mirror of the International X-ray Observatory (IXO) are about 3 m2 at 1keV, 0.65 m2 at 6 keV and 150 cm2 at 30 keV. Because of its large dimension, the telescope cannot be realized as a monolithic structure but rather it requires the integration and assembly in the telescope optical bench of a number of basic module units, called X-ray Optical Unit (XOU). We are currently studying a method for the production of these basic units that is based on the slumping technology for the production of thin glass segmented mirrors. It foresees the implementation of a stacking integration concept based on the use of reinforcing ribs connecting the glass segments in order to create very stiff structures. This paper reports on the last design of the single optical module and describe the results of FEM analyses that show how it is possible to use an innovative approach to the integration of the slumped glass foils.

Slumping technique for the manufacturing of a representative x-ray grazing incidence mirror module for future space missions

The Astronomical Observatory of Brera (INAF-OAB, Italy), with the financing support of the European Space Agency (ESA), has concluded a study regarding a glass shaping technology for the production of grazing incidence segmented x-ray optics. This technique uses a hot slumping phase, in which pressure is actively applied on thin glass foils being shaped, to form a cylindrical approximation of Wolter I x-ray segments, and a subsequent cold slumping phase, in which the final Wolter I profile is then freeze into the glass segments during their integration in elemental X-ray Optical Units. The final goal of this study was the manufacturing of a prototype containing a number of slumped pair plates (meaning parabola and hyperbola couples) having representative dimensions to be tested both in UV light and in x-rays at the Panter facility (Germany). In this paper, the INAF-OAB slumping technique, comprising a shaping step and an integration step is described, together with the results obtained on the manufactured prototype modules: the first prototype was aimed to test the ad-hoc designed and built semi-automatic Integration MAchine (IMA) and debug its control software. The most complete module comprises 40 slumped segments of Schott D263 glass type of dimension 200 mm x 200 mm and thickness of 0.4 mm, slumped on Zerodur K20 mould and stacked together through glued BK7 glass structural ribs to form the first entire x-ray optical module ever built totally composed by glass. A last prototype was aimed at demonstrate the use of Schott glass AF32 type instead of D263. In particular, a new hot slumping experimental set-up is described whose advantage is to permit a better contact between mould and glass during the shaping process. The integration procedure of the slumped segments into the elemental module is also reviewed.

The ASTRI SST-2M prototype for the next generation of Cherenkov telescopes: structure and mirrors

The next generation of Imaging Atmospheric Cherenkov Telescope will explore the uppermost end of the Very High Energy domain up to about few hundreds of TeV with unprecedented sensitivity, angular resolution and imaging quality. To this end, the Italian National Institute of Astrophysics (INAF) is currently developing a scientific and technological telescope prototype for the implementation of the Cherenkov Telescope Array (CTA) observatory. The Italian ASTRI program foresees the full design, development, installation and calibration of a Small Size 4-meter class Telescope, adopting an aplanatic, wide-field, double-reflection optical layout in a Schwarzschild-Couder configuration. In this paper we discuss about the technological solutions adopted for the telescope and for the mirrors. In particular we focus on the structural and electro-mechanical design of the telescope, now under fabrication. The results on the optical performance derived from mirror prototypes are here described, too.

An integration machine for the assembly of the x-ray optic units based on thin slumped glass foils for the IXO mission

The International X-ray Observatory (IXO) is a joint mission concept studied by the ESA, NASA, and JAXA space agencies. The main goal of the mission design is to achieve a large effective area (>2.5m2 at 1 keV) and a good angular resolution (5 arcsec HEW at 1 keV) at the same time. The Brera Astronomical Observatory - INAF (Italy), under the support of ESA, is developing a method for the realization of the X-Ray Optical Units, based on the use of slumped thin glass segments to form densely packed modules in a Wolter type I optical configuration. In order to reach the very challenging integration requirements, it has been developed an innovative assembly approach for aligning and mounting the IXO mirror segments. The method is based on the use of an integration mould for each foil. In particular the glass segment is forced to adhere to the integration mould in order to maintain the optimal figure without deformations until the integration of the foil in the stack is completed. In this way an active correction for major existing figure errors after slumping is also achieved. Moreover reinforcing ribs are used in order to connect the facets to each-other and to realize a robust monolithic stack of plates. In this paper we present the design, the development and the validation status of a special Integration Machine (IMA) that has been specifically developed to allow the integration of the Plate Pairs into prototypal X-Ray Optical Unit stacks.

IXO x-ray mirrors based on slumped glass segments with reinforcing ribs: optical and mechanical design, image error budget, and optics unit integration process

The International X-ray Observatory (IXO) is being studied as a joint mission by the NASA, ESA and JAXA space agencies. The main goals of the mission are large effective area (>3m2 at 1 keV) and a good angular resolution (<5 arcsec HEW at 1 keV). This paper reports on an activity ongoing in Europe, supported by ESA and led by the Brera Astronomical Observatory (Italy), aiming at providing an alternative method for the realization of the mirror unit assembly. This is based on the use of thin glass segments and an innovative assembly concept making use of glass reinforcing ribs that connect the facets to each-other. A fundamental challenge is the achievement with a hot slumping technique of the required surface accuracy on the glass segments. A key point of the approach is represented by the alignment of the mirror segments and co-alignment of the mirror pairs assembled together. In this paper we present the mirror assembly conceptual design, starting from the design of the optical unit, the error budgets contributing to the image degradation and the performance analysis to assess error sensitivities. Furthermore the related integration concept and the preliminary results obtained are presented.

Evaluation of the surface strength of glass plates shaped by hot slumping process

Abstract. Hot slumping technology is under development by several research groups in the world for the realization of grazing-incidence segmented mirrors for x-ray astronomy, based on thin glass plates shaped over a mold at temperatures above the transformation point. The performed thermal cycle and related operations might have effects on the strength of the glass, with consequences for the structural design of the elemental optical modules and, consequently, on the entire x-ray optic for large astronomical missions such as IXO and ATHENA. The mechanical strength of glass plates after they underwent the slumping process was tested through destructive double-ring tests in the context of a study performed by the Astronomical Observatory of Brera with the collaboration of Stazione Sperimentale del Vetro and BCV Progetti. The entire study was done on more than 200 D263 Schott borosilicate glass specimens of dimensions 100  mm×100  mm and a thickness 0.4 mm, either flat or bent at a radius of curvature of 1000 mm through the pressure-assisted hot slumping process developed by INAF-OAB. The collected experimental data have been compared with nonlinear finite element model analyses and treated with the Weibull statistic to assess the current IXO glass x-ray telescope design, in terms of survival probability, when subjected to static and acoustic loads characteristic of the launch phase. The paper describes the activities performed and presents the obtained results.

The optics system of the New Hard X-ray Mission: design and development

The New Hard X-ray Mission (NHXM) project will be operated by 2016 and is currently undergoing the Phase B study. It is based on 4 hard X-ray optics modules, each formed by 60 evenly spaced multilayer coated Wolter I mirror shells. An extensible bench is used to reach the 10 m focal length. The Wolter I monolithic substrates with multilayer coating are produced in NiCo by electroforming replication. Three of the mirror modules will host in the focal plane a hybrid a detector system (a soft X-ray Si DEPFET array plus a high energy CdTe detector). The detector of the fourth telescope will be a photoelectric polarimeter with imaging capabilities, operating from 2 up to 35 keV. The total on axis effective area of the three telescopes at 1 keV and 30 kev is of 1500 cm2 and 350 cm2 respectively, with an angular resolution of 20 arcsec HEW at 30 keV. In this paper we report on the design and development of the multilayer optics of the mission, based on thin replicated Ni mirror shells.