# Presentation: 565541

## The Constellation-X Spectroscopy X-ray Telescope:  Recent Technology Development

***S.O’Dell, W. Jones / MSFC******P. Reid / SAO***

## Outline

**SXT requirements and conceptual design**
**Recent progress**
**Mirror segment characterization**
**Separating intrinsic segment properties from mounting and metrology**
**Mirror pair alignment**
**Near term plans and challenges**

**The “new” Constellation-X**

## SXT Flight Mirror Assembly Requirements (per mirror)

**The fundamental SXT performance requirements have not changed over the past several years**
**Emphasis on performance margin (extra effective area) and need to approach angular resolution goal has increased**

**Notes:**
From Mission Configuration Trade Summary: 
Energy (keV)                                                0.25        1.25            6         10
Effective area/mirror (cm^2) 
    Estimate                                                 250         3750       1500      250
    Reference with Off-Plane:                      476        4350       1440       499
    F-10/4/1.6A                                              307        4594       1731       525
Mass/SXT F-10/4/1.6A:  576 kg
Mass of pre/post collimators:??

Diep:  the third line in this table is the correct one for Effective Area – we would be using the F-10/4/1.6A design in either configuration.  I put Jeff’s new mass estimate in the table.  The areas I put in the top EA box are the raw telescope areas reduced by the 12% structural blockage that we agreed to for the trade study.  The remainder of the “throughput” factors reduce this area to the figures in the F-10/4/1.6A row above, which may go in another table somewhere.

## SXT Mirror Reference Design Concept  

**SXT Incorporates Modular Construction and Segmented Wolter I Mirrors**** ****	****	**

**Primary (Paraboloid)**
**(12 Outer Submodules)**

**Secondary (Hyperboloid)**
**(6 Inner, 12 Outer submodules)**

**Primary (Paraboloid)**
**(6 Inner submodules)**

**Ring Structure Assembly**

**1.6 m diameter ****at**** P-H ****intersection**

**2x20 cm**
**mirror**
**length**

## SXT Mirror Reference Design Parameters

| Parameter | Description |
| --- | --- |
| Design | Segmented Wolter I |
| Segment substrate material | Thermally formed glass |
| X-ray reflecting surface | Gold |
| Number of nested shells | 127 (inner); 89 (outer) |
| Total number of segments | 3660 |
| Mirror segment length | 20 cm |
| Number of modules | 6 (inner); 12 (outer)  |
| Module housing composition | Titanium alloy, CTE-matched to substrate |
| Module support structure | Composite |
| Largest segment surface area | 0.08 m2 |
| Substrate density | 2.5 g/cm3 |
| Mirror segment thickness | 0.44 ± 0.02 mm |
| Mirror segment microroughness | 6 Angstrom RMS |
| FMA mechanical envelope | 1.68 m dia x 1.98 m  |

**    ****Unchanged from four spacecraft configuration**

## New Constellation-X Configuration

**Single spacecraft consistent with Delta-IV (heavy) mass and size envelope, with no extendable optical bench**
**Numerous optical configurations studied**
**Number of mirrors**
**Outer diameter**
**Focal length**
**Current configuration is most consistent with mission science requirements and launch constraints**
**4 mirrors with 10 m focal length and 1.6 m diameter**
**Modular design would allow straightforward adaptation to different mirror parameters **
**Current technology development derives from 8.6 m focal length design**
***More substantive change to SXT technology development comes from substantial budget cut (February 2006)***

## SXT Reference Concept Angular Resolution Error Budget

## Mirror Segments - Recent Progress

**Demonstrated that formed substrates faithfully and consistently reproduce the forming mandrel surface at low spatial frequencies**
**Improved the formed and replicated mirror quality by reduction of size and number of particulates (dust) on surface**
**Invested considerable effort reducing environmental dust in mirror lab**
**Demonstrated that replication with ~10 μm epoxy layer can smooth out mid-frequency errors without causing significant distortion to low order figure**
**Demonstrated feasibility of producing mirror segments meeting the error budget requirement without replication **
**Low and mid frequency improvement is likely if more precise forming mandrels are used**
**Demonstrated that low order figure distortions are very sensitive to segment orientation and how it is held**
**Developed a forming mandrel release layer that is very smooth and durable, and reduces mid-frequency roughness introduced by forming**
**Possible to apply using robotic spraying (developed for epoxy)**
**Process improvements still being sought**

## Mirror Segments - Technical challenges

**We have a clear understanding of elements of producing mirror segments**
**Three largely decoupled spatial frequency domains **
**Low order - 2-20 cm**
**Mid-frequency - 0.1-2 cm**
**High-frequency (microroughness) <0.1 cm**
**Low order**
**Determined by forming; not improved by replication**
**Regime where distortions due to gravity, mechanical stresses appear**
**Dictate forming mandrel requirements**
**Mid frequency**
**Imparted to substrate during forming**
**Very sensitive dependence on physics of forming process**
**Very sensitive to presence of particulates**
**Corrected by epoxy replication**
**Microroughness**
**Substrate material has excellent microroughness; preserved during forming**
**Replication introduces entirely new microsurface - this places requirements on replication mandrel microroughness (superpolishing is necessary)**

## Spatial Frequency Domains

***Figure***

***Mid-frequency***

***Microroughness***

## Mirror Segment Metrology Allocation vs. Measurement(ordered by HPD contribution)

|  Parameters | Units | Allocation | Status | Instrumentation | Plan/Comments |
| --- | --- | --- | --- | --- | --- |
| AXIAL FIGURE  |  |  |  |  |   |
| Slope  | arcsec, rms  | 0.75 | 0.35 | Interferometer |   |
| Mid-frequency  | nm, rms  | 2.53 | 0.5 | Interferometer, Bauer200 |   |
| Micro-roughness | nm, rms | 0.19 | 0.1 | Microinterferometer |   |
| Sag  | μm, pv | 0.04 | ―  | Interferometer, MMTC | 10-point mount will improve accuracy.  Plan for better thermal control.  Gravity back out model & verification required. |
| Delta-delta-radius  | arcsec, pv | 0.22 | ― | MMTC, Null lens | MMTC ∆∆R on mirror segment dominated by room thermal changes; Null lens needs permanent mount & calibration. |
| Roundness 
 | μm, pv
 | 1.58 | 3.5
 | MMTC
 | Dominated by room thermal changes (range during test from 2.7μm to 3.5 μm).  Plan for better thermal control. |
| Cone-angle
 | arcsec
 | 3.16
 | ―
 | MMTC | Optipro/MMTC. 10-point mount will improve accuracy.  Plan for better thermal control. ±0.65 arcsec measured on solid calibration cylinder. |
| Average radius
 | μm | 10.4
 | ― | MMTC | Optipro/MMTC. 10-point mount will improve accuracy.  Plan for better thermal control. ±1.8 μm measured on solid calibration cylinder. |

## 2D Contour plot of recent substrate

**98 profiles measured; piston and tilt removed**
**Single mandrel profile expanded to 2D**
**RMS height error =0.30 ****μ****m**
**Difference map represents **_**upper limit**_** of actual difference**
**Large deviations due to dust particles**
**Large deviation at top due to mounting fixture**

## Comparison of mandrel and four consecutive substrates

**Compare single substrate (120, 121, 122, and 124) profiles to the mandrel profile**
**Low order axial and azimuthal terms removed**
**Calculate RMS difference for processed data and scaled data ( mandrel axial scale factor 0.97)**
**RMS of unscaled data ~50 nm and scaled data ~30 nm**
**RMS error is dominated by large differences in the valleys at about 170 mm, 120, and 20 mm axial locations **
**Is the mandrel treatment filling the valleys at 20 mm and 170 mm?**

|  | Mandrel-substrate RMS height difference |  |
| --- | --- | --- |
|  | Raw data (nm) | Scaled data (nm) |
| 120 | 44 | 30 |
| 121 | 50 | 32 |
| 122 | 49 | 28 |
| 124 | 51 | 32 |

**Substrates have consistently high quality, and closely match mandrel**

## Understanding distortions introduced during metrology

**Measuring axial profiles in the “upright” and “inverted” orientations  allow separation of instrinic mirror errors from those induced by mounting**
**1st through 5th order errors (low frequency) are dominated by mounting stresses, as shown in the PSD plot, top right**
**~6th order and higher errors are inherent to the part.  There errors are only on the order of 10-30 nm **
**Scan difference plot reveals distortion due to 3-point mount as well as registration differences due to shift in baseline**

**Biggest challenge**
**is mounting **
**segments without**
**Imparting stress**

## Mirror Segment Figure Improvement

## Mirror Segments - Challenges to Consistently Meeting Requirement

- Improvement of glass forming environment, including a clean/vacuum oven
- Better understanding of the surface physics of forming
- Ability to perform mechanical/thermal modeling of forming
- Improvement of the glass sheet cleaning process
- Better control of the epoxy replication environment: a mandrel coating chamber at GSFC
- Improved metrology of segment figure
**Virtually impossible to measure free-standing segment, especially 2nd order sag**
**Such measurements are largely irrelevant - expect coupling between segment and mount (can’t independently determine error budget terms)**
**We are building a 10-point mount to emulate conditions in housing, which facilitates 2D surface metrology**

## Typical Primary/Secondary (P/S) Module Stack up: 		

- Reference FMA Mounting Concept

**Typical Strut (5 Top, 5 bottom on each Submodule)**

**S Submodule**

**P Submodule**

**FMA Ring Structure Assembly**
** ****(“Wagon Wheel”)**

**This concept uses flexures**
** ****to attach the P and S sub-modules**
** ****together, as well as, to the Ring**
** ****Structure Assembly**

- A

- A

**Typical Flexure Assembly**
**4 Places**

## OAP2 unit for mirror pair alignment and mounting demonstration

**Mirror surfaces**

**Cylindrical null lens assembly**

**Retroreflector**

**Fully assembled OAP2 unit in alignment faclity**

**~95 percent of each mirror surface is viewable by instrumentation at normal incidence**

**Actuator plate**
**(1 of 4)**

## Alignments within OAP2 driven by precise piezoelectric actuators

**CMM Contact probe**

**Flexure**

**Set screws**

**Actuator support plate**

## Alignment combines focal plane measurements with surface interferometry

**Centroid Detector Assembly (CDA) originally developed for aligning AXAF mirrors (<0.1 arc second accuracy)**
**CDA samples only a portion of surface, defined by aperture stops; only locates centroid of return beam**
**Observed patterns are ambiguous; prealignment using collimated beam breaks degeneracy**
**Only way to determine shape of segment is simultaneous figure measurement using   interferometer**

**Aperture Plate**

**CDA**

**Mirror**
**or pair**

**Interferometer**

**Flat mirror**

**Large**
**conical**
**beam**

## OAP2-S alignment status

**A secondary mirror segment has been aligned in the CDA facility and simultaneously imaged with an interferometer through the conical null lens.**
**The “best” alignment is a compromise between the best mirror segment focusing that can be achieved by monitoring the CDA only, and the best mirror segment figure that can be achieved by monitoring the interferogram only.**
**Graphs to the right show the CDA focus and “first light” alignment using the conical null lens.**
**Better alignment has since been achieved.  It appears that we can routinely achieve alignment quality on the order of 16” HPD (2-reflection equivalent).**
**Details in S. Owens talk**

## Mirror Pair Performance Prediction

- Mirror segment

- Visible area
- in single null
- lens image

**Performance prediction based on ray trace using fit data from area of mirror segment visible in null lens (37 deg x 185 mm)**
**Measured figure error of secondary applied to ideal primary mirror segment to get a 2-reflection model**
**HPD = 5.1” (no scatter)**
**HPD = 14.6” (figure error and scatter models on both surfaces)**
**Major unknowns are primary figure and misalignment**

- Mounting points

**Ray traced**
**2-reflection**
**image in**
**focal plane**

## Plans for Coming Year (and Beyond)

***Mount and align one or more pairs of mirror segments***
***Perform in situ full surface metrology within OAP2 mount***
***Demonstrate that aligned segments meet the Constellation-X HPD requirement***
***Quantify residual errors to determine most significant contributions***
***Compare 3D segment surface measurements and distortions (using special metrology mount) with optical and mechanical models***
***Verify performance of aligned mirror pair(s) in X-rays; compare with predictions from metrology***
***Continue development of alignment procedures***
***Introduce next generation Piezo actuators***
***Integrate collimated beam, surface profile interferometry, and CDA***
***Refigure forming mandrel pair to allow 3 arc second HPD (Con-X goal)***
***Procure and test 50 cm “slab” forming mandrel***
***Couple with thermo-mechanical modeling of forming process***
***Initiate conversion of forming to “flight-like” mandrels***
***Involve industry in studies of Flight Mirror Assembly and mandrel fabrication***
***Mandrel fabrication is critical path of the  program - need to identify multiple suppliers***
***Mounting process could benefit from independent engineering study***
***New funding reductions will significantly delay all mirror technology development, and could result in irretrievable loss of knowledge***

## Technology Development Roadmap Summary  

|  | Optical Assembly Pathfinder |  | Mass Alignment Pathfinder |  Engineering Unit | Subassembly |  |
| --- | --- | --- | --- | --- | --- | --- |
|  | OAP #1 | OAP #2 |  |  |  |  |
| Configuration |  |  |  |  |  |  |
| Module Type | Inner | Inner | Inner | Two inner modules | NASA Testbed – Outer + Inner | Industry  Prototype –Outer + Inner |
| Housing Material | Aluminum | Titanium | Titanium | Titanium | Titanium | Titanium |
| Focal Length | 8.4 m | 8.4 m | 8.4 m | 10 m or 8.4 m (TBD) | 10.0 m | 10.0 m |
| Nominal mirror segment Diameter(s) | 50 cm | 50 cm | 50 cm | 50 cm | 160 cm120 cm100 cm, 50 cm± | 160 cm120 cm100 cm,  50 cm± |
| Goals | Align 1 mirror segment pair (P&H)
Evaluate mirror assembly design, alignment and metrology 
 | Align 1 mirror segment pair 
Evaluate segment performance and stability in mount
Evaluate mirror bonding
X-ray test
Vibration test | Align up to 3 mirror segment pairs to achieve<12.5 arcsec
Evaluate tooling for mass alignment 
Vibration & X-ray tests

 | Fabricate segments from slab mandrels
Align module to module. 
 X-ray and environmental tests
Technology transfer to industry
Evaluate assy gravity sag
 | Form largest mirror segments
Demonstrate  reference subassembly design
Environmental  and X-ray test

 | Demonstrate flight prototype
Environmental and X-ray test
Industry build |
| TRL –  Mirror segment | TRL 3 | TRL 4/5 |  | TRL 6 |  |  |
| TRL –  Assembly | TRL 3 | TRL 3/4 | TRL 5   | TRL 6 |  |  |
| Timeframe | Q2 of FY03 | Q2 of FY06 | 2006 - 2009 |  |  |  |
| Technology Gate |  |  |  |  |  |  |

## Summary

***Significant progress made in some areas of SXT mirror development  despite substantial funding reduction***
***High quality substrates made reliably and faithfully reproduce mandrel surface***
***We understand the origin of many of the substrate errors ***_***and how to remove them***_
***Substrate performance is limited by mandrel figure***
***Alignment principles have been demonstrated; we are close to having a segment pair aligned***
***Substantial evidence exists that mirrors have correct overall shape***
***Metrology uncertainties limit our knowledge of the segment quality***
***Two new tools (MMTC, high speed interferometer) coming on line to address these uncertainties***
***Mounting has been a crucial limitation of metrology***
***We have not yet measured the true 3D shape of a segment***
***Strong coupling between mounting and alignment is becoming understood***
***See talk by Scott Owens***
***X-ray test using aligned segment pair should yield performance consistent with Con-X requirement***
***Supporting metrology data will ensure an accurate performance prediction***