Stephen D. Jacobs

Thermal conductivity of dielectric thin films

A direct reading thermal comparator has been used to measure the thermal conductivity of dielectric thin‐film coatings. In the past, the thermal comparator has been used extensively to measure the thermal conductivity of bulk solids, liquids, and gases. The technique has been extended to thin‐film materials by making experimental improvements and by the application of an analytical heat flow model. Our technique also allows an estimation of the thermal resistance of the film/substrate interface which is shown to depend on the method of film deposition. The thermal conductivity of most thin films was found to be several orders of magnitude lower than that of the material in bulk form. This difference is attributed to structural disorder of materials deposited in thin‐film form. The experimentation to date has primarily centered on optical coating materials. These coatings, used to enhance the optical properties of components such as lenses and mirrors, are damaged by thermal loads applied in high‐power las...

Experiments and observations regarding the mechanisms of glass removal in magnetorheological finishing

Recent advances in the study of the magnetorheological finishing (MRF) have allowed for the characterization of the dynamic yield stress of the magnetorheological (MR) fluid, as well as the nanohardness (H(nano)) of the carbonyl iron (CI) used in MRF. Knowledge of these properties has allowed for a more complete study of the mechanisms of material removal in MRF. Material removal experiments show that the nanohardness of CI is important in MRF with nonaqueous MR fluids with no nonmagnetic abrasives, but is relatively unimportant in aqueous MR fluids or when nonmagnetic abrasives are present. The hydrated layer created by the chemical effects of water is shown to change the way material is removed by hard CI as the MR fluid transitions from a nonaqueous MR fluid to an aqueous MR fluid. Drag force measurements and atomic force microscope scans demonstrate that, when added to a MR fluid, nonmagnetic abrasives (cerium oxide, aluminum oxide, and diamond) are driven toward the workpiece surface because of the gradient in the magnetic field and hence become responsible for material removal. Removal rates increase with the addition of these polishing abrasives. The relative increase depends on the amount and type of abrasive used.

Demonstration of high efficiency third harmonic conversion of high power Nd-glass laser radiation

Abstract We report on efficient conversion from 1.054 μm to 0.35 μm by third harmonic generation in two Type II KDP crystals. Energy conversion efficiencies of up to 80% have been measured under conditions applicable to large glass laser systems. A new tripling scheme used for these experiments requires a minimum of optical components and is insensitive to exact crystal alignment and laser beam divergence. A convenient scaling law allows tripling optimization for many different laser conditions.

Subsurface damage in some single crystalline optical materials

We present a nondestructive method for estimating the depth of subsurface damage (SSD) in some single crystalline optical materials (silicon, lithium niobate, calcium fluoride, magnesium fluoride, and sapphire); the method is established by correlating surface microroughness measurements, specifically, the peak-to-valley (p-v) microroughness, to the depth of SSD found by a novel destructive method. Previous methods for directly determining the depth of SSD may be insufficient when applied to single crystals that are very soft or very hard. Our novel destructive technique uses magnetorheological finishing to polish spots onto a ground surface. We find that p-v surface microroughness, appropriately scaled, gives an upper bound to SSD. Our data suggest that SSD in the single crystalline optical materials included in our study (deterministically microground, lapped, and sawed) is always less than 1.4 times the p-v surface microroughness found by white-light interferometry. We also discuss another way of estimating SSD based on the abrasive size used.

Physics of loose abrasive microgrinding

This study examined the physics of loose abrasive microgrinding (grinding with micron and submicron sized abrasives). More specifically, it focused on the transition from brittle to ductile mode grinding which occurs in this region of abrasive sizes. Process dependency on slurry chemistry was the primary area of emphasis and was studied for diamond abrasives varying in size from 3.0 to 0.75 microm on both ULE and Zerodur, with emphasis on ULE. Ductile mode grinding was achieved with smaller abrasives, as expected, however two significant discoveries were made. The first observation was that by simply changing slurry chemistry, it was possible to induce the transition from brittle fracture to ductile mode grinding in ULE. This transition point could be intentionally moved about for diamonds 3.0-0.75 microm in diameter. For any given abrasive size within these limits, either brittle fracture or ductile removal may be achieved, depending on the slurry used to suspend the diamonds. Several slurries were studied, including water, a series of homologous n-alcohols, and other solvents chosen for properties varying from molecular size to dielectric constant and zeta potential. The study revealed that this slurry dependency is primarily a Rebinder effect. The second finding was that a tremendous amount of surface stress is introduced in loose abrasive ductile mode grinding. This stress was observed when the Twyman Effect in ULE plates increased by a factor of 4 in the transition from the brittle to the ductile mode. An assessment of the cause of this stress is discussed.

Slurry particle size evolution during the polishing of optical glass

The particle size distribution of aqueous metal-oxide slurries can evolve during the polishing of optical glass in response to changes in mechanical and chemical process factors. The size-evolution phenomenon and its consequences were systematically studied in a planar continuous-polishing process. The concurrent application of electrokinetic techniques to characterize common optical shop materials has contributed new insight into the nature of silicate glass polishing by demonstrating the pivotal role of fluid chemistry, particularly pH, in maintaining electrokinetically favorable conditions for a welldispersed polishing agent. According to the proposed slurry-charge-control effect, a well-dispersed polishing agent is the key to obtaining the smoothest possible glass surfaces, especially when a recirculated slurry is used.

Surface microroughness of optical glasses under deterministic microgrinding

Deterministic microgrinding of precision optical components with rigid, computer-controlled machining centers and high-speed tool spindles is now possible on a commercial scale. Platforms such as the Opticam systems at the Center for Optics Manufacturing produce convex and concave spherical surfaces with radii from 5 mm to ∞, i.e., planar, and work diameters from 10 to 150 mm. Aspherical surfaces are also being manufactured. The resulting specular surfaces have a typical rms microroughness of 20 nm, 1 μm of subsurface damage, and a figure error of less than 1 wave peak to valley. Surface roughness under deterministic microgrinding conditions (fixed infeed rate) with bound abrasive diamond ring tools with various degrees of bond hardness is correlated to a material length scale, identified as a ductility index, involving the hardness and fracture toughness of glasses. This result is in contrast to loose abrasive grinding (fixed nominal pressure), in which surface microroughness is determined by the elastic stiffness and the hardness of the glass. We summarize measurements of fracture toughness and microhardness by microindentation for crown and flint optical glasses, and fused silica. The microindentation fracture toughness in nondensifying optical glasses is in good agreement with bulk fracture toughness measurement methods.

Magnetorheological finishing: a deterministic process for optics manufacturing

Finish polishing of optics with magnetic media has evolved extensively over the past decade. Of the approaches conceived during this time, the most recently developed process is called magnetorheological finishing (MRF). In MRF, a magnetic field stiffens a fluid suspension in contact with a workpiece. The workpiece is mounted on the rotating spindle of a computer numerically controlled machine. Driven by an algorithm for machine control that contains information about the MRF process, the machine deterministically polishes out the workpiece by removing microns of subsurface damage, smoothing the surface to a microroughness of 10 angstroms rms, and correcting surface figure errors to less than 0.1 micrometers p-v. Spheres and aspheres can be processed with the same machine set-up using the appropriate machine program. This paper describes MRF and gives examples which illustrate the capabilities of a pre-prototype machine located at the Center for Optics Manufacturing.

High-power phosphate-glass laser system: design and performance characteristics.

A one-beam prototype of a large twenty-four-beam phosphate-glass laser system has been built and tested. Basic design characteristics include Nd-doped phosphate glass, rod amplifiers up to 90-mm diam, the propagation of a circularly polarized beam, extensive spatial filtering and imaging, and the use of large-aperture Pockels cells. The prototype system has demonstrated focusable power in excess of 750 GW/beam at 50-psec full width at half-maximum (FWHM) pulse duration and has delivered 165 J of focusable energy in a 500-psec (FWHM) pulse. Maximum beam brightness has been measured to be 4 x 10(19) W/cm(2) .sr at a firing rate of 2 shots/hr. Peak-to-background energy contrast of 10(8) has been achieved with this system. A detailed description of the system design and performance is presented.

Removal rate model for magnetorheological finishing of glass

Magnetorheological finishing (MRF) is a deterministic subaperture polishing process. The process uses a magnetorheological (MR) fluid that consists of micrometer-sized, spherical, magnetic carbonyl iron (CI) particles, nonmagnetic polishing abrasives, water, and stabilizers. Material removal occurs when the CI and nonmagnetic polishing abrasives shear material off the surface being polished. We introduce a new MRF material removal rate model for glass. This model contains terms for the near surface mechanical properties of glass, drag force, polishing abrasive size and concentration, chemical durability of the glass, MR fluid pH, and the glass composition. We introduce quantitative chemical predictors for the first time, to the best of our knowledge, into an MRF removal rate model. We validate individual terms in our model separately and then combine all of the terms to show the whole MRF material removal model compared with experimental data. All of our experimental data were obtained using nanodiamond MR fluids and a set of six optical glasses.