Three-dimensional laser window formation for industrial application

The NASA Lewis Research Center has developed and implemented a unique process for forming flawless three-dimensional, compound-curvature laser windows to extreme accuracies. These windows represent an integral component of specialized nonintrusive laser data acquisition systems that are used in a variety of compressor and turbine research testing facilities. These windows are molded to the flow surface profile of turbine and compressor casings and are required to withstand extremely high pressures and temperatures. This method of glass formation could also be used to form compound-curvature mirrors that would require little polishing and for a variety of industrial applications, including research view ports for testing devices and view ports for factory machines with compound-curvature casings. Currently, sodium-alumino-silicate glass is recommended for three-dimensional laser windows because of its high strength due to chemical strengthening and its optical clarity. This paper discusses the main aspects of three-dimensional laser window formation. It focuses on the unique methodology and the peculiarities that are associated with the formation of these windows.