Production of Ultra-Light Normal Incidence Mirrors

Mirrors fabrication for large aperture telescopes is an important aspect in space exploration programs. One of the cost effective techniques to obtain such mirrors is electroplating of Ni-Co alloys from sulfamate solution. The Center for Irradiation of Materials at Alabama A&M University - Research Institute has been involved in a NASA-MSFC project for producing ultra-light Ni-Co alloy mirrors since the summer of year 2000. The goal of this project is to obtain ultra-light, high strength electroformed large aperture normal incidence replicated mirrors, (weighting less than 5 kg/m2), free of stress, with a good figure and reproducible thickness variation. In order to simplify the control of parameters such as temperature gradient, concentration gradient, distribution of the electric field lines and flow control, the proposed geometry involves a cylindrical main tank contained in another cylindrical tank, which plays the role of a weir. Designs were created to accommodate the new horizontal position of the mandrel and the pipes fitting through the outer tank's lid. The inner tank contains the working electrodes and a series of sensors for monitoring temperature, flow, stress and pH. The outer tank holds the electric heaters, the filters and a part of the piping system. Another two tanks complete the setup and serve for rinsing/preheating and equilibrating the electroplating bath. This paper will describe advantages of the new experimental setup and the parameters achieved in the electroplating bath for the proposed geometry.