ALBERT

Description: We present highlights from the American Society for Precision Engineering's 2004 winter topical meeting entitled Free-Form Optics: Design, Fabrication, Metrology, Assembly. We emphasize those papers that are most relevant to astronomical optics. Optical surfaces that transcend the bounds of rotational symmetry have been implemented in novel optical systems with fantastic results since the release of Polaroid's first instant camera. Despite these successes, free-form optics have found only a few niche applications and have yet to enter the mainstream. The purpose of this meeting is to identify the state of the art of free-form optics design, fabrication, metrology and assembly and to identify the technical and logistical challenges that inhibit their widespread use. Issues that will be addressed include: What are free-form optics? How can optical systems be made better with free-form optics? How can designers use free-form optics? How can free-form optics be fabricated? How can they be measured? How are free-form optical systems assembled? Control of multi-axis systems.

Description: The James Webb Space Telescope (JWST) is a 6.6m diameter, segmented, deployable telescope for cryogenic IR space astronomy (approximately 40K). The JWST Observatory architecture includes the Optical Telescope Element and the Integrated Science Instrument Module (ISIM) element that contains four science instruments (SI) including a Guider. The ISM optical metering structure is a roughly 2.2x1.7x2.2m, asymmetric frame that is composed of carbon fiber and resin tubes bonded to invar end fittings and composite gussets and clips. The structure supports the SIs, isolates the SIs from the OTE, and supports thermal and electrical subsystems. The structure is attached to the OTE structure via strut-like kinematic mounts. The ISIM structure must meet its requirements at the approximately 40K cryogenic operating temperature. The SIs are aligned to the structure's coordinate system under ambient, clean room conditions using laser tracker and theodolite metrology. The ISIM structure is thermally cycled for stress relief and in order to measure temperature-induced mechanical, structural changes. These ambient-to-cryogenic changes in the alignment of SI and OTE-related interfaces are an important component in the JWST Observatory alignment plan and must be verified. We report on the planning for and preliminary testing of a cryogenic metrology system for ISIM based on photogrammetry. Photogrammetry is the measurement of the location of custom targets via triangulation using images obtained at a suite of digital camera locations and orientations. We describe metrology system requirements, plans, and ambient photogrammetric measurements of a mock-up of the ISIM structure to design targeting and obtain resolution estimates. We compare these measurements with those taken from a well known ambient metrology system, namely, the Leica laser tracker system. We also describe the data reduction algorithm planned to interpret cryogenic data from the Flight structure. Photogrammetry was selected from an informal trade study of cryogenic metrology systems because its resolution meets sub-allocations to ISIM alignment requirements and it is a non-contact method that can in principle measure six degrees of freedom changes in target location. In addition, photogrammetry targets can be readily related to targets used for ambient surveys of the structure. By thermally isolating the photogrammetry camera during testing, metrology can be performed in situ during thermal cycling. Photogrammetry also has a small but significant cryogenic heritage in astronomical instrumentation metrology. It was used to validate the displacement/deformation predictions of the reflectors and the feed horns during thermal/vacuum testing (90K) for the Microwave Anisotropy Probe (MAP). It also was used during thermal vacuum testing (100K) to verify shape and component alignment at operational temperature of the High Gain Antenna for New Horizons. With tighter alignment requirements and lower operating temperatures than the aforementioned observatories, ISIM presents new challenges in the development of this metrology system.

Description: The James Webb Space Telescope (JWST) is a 6.6m diameter, segmented, deployable telescope for cryogenic IR space astronomy (approximately 40K). The JWST Observatory architecture includes the Optical Telescope Element (OTE) and the Integrated Science Instrument Module (ISIM) element that contains four science instruments (SI) including a Guider. The SIs and Guider are mounted to a composite metering structure with outer dimensions of 2.1 x 2.2 x 1.9m. The SI and Guider units are integrated to the ISIM structure and optically tested at NASA/Goddard Space Flight Center as an instrument suite using an OTE SIMulator (OSIM). OSIM is a high-fidelity, cryogenic JWST telescope simulator that features a approximately 1.5m diameter powered mirror. The SIs are aligned to the structure's coordinate system under ambient, clean room conditions using laser tracker and theodolite metrology. Temperature-induced mechanical SI alignment and structural changes are measured using a photogrammetric measurement system at ambient and cryogenic temperatures. OSIM is aligned to the ISIM mechanical coordinate system at the cryogenic operating temperature via internal mechanisms and feedback from alignment sensors in six degrees of freedom. SI performance, including focus, pupil shear and wavefront error, is evaluated at the operating temperature using OSIM. We present an updated plan for the assembly and ambient and cryogenic optical alignment, test and verification of the ISIM element.

Description: For many optical systems the properties and alignment of the internal apertures and pupils are not critical or controlled with high precision during optical system design, fabrication or assembly. In wide angle imaging systems, for instance, the entrance pupil position and orientation is typically unconstrained and varies over the system s field of view in order to optimize image quality. Aperture tolerances usually do not receive the same amount of scrutiny as optical surface aberrations or throughput characteristics because performance degradation is typically graceful with misalignment, generally only causing a slight reduction in system sensitivity due to vignetting. But for a large deployable space-based observatory like the James Webb Space Telescope (JWST), we have found that pupil alignment is a key parameter. For in addition to vignetting, JWST pupil errors cause uncertainty in the wavefront sensing process that is used to construct the observatory on-orbit. Furthermore they also open stray light paths that degrade the science return from some of the telescope s instrument channels. In response to these consequences, we have developed several pupil measurement techniques for the cryogenic vacuum test where JWST science instrument pupil alignment is verified. These approaches use pupil alignment references within the JWST science instruments; pupil imaging lenses in three science instrument channels; and unique pupil characterization features in the optical test equipment. This will allow us to verify and crosscheck the lateral pupil alignment of the JWST science instruments to approximately 1-2% of their pupil diameters.

Description: We describe the use of LIDAR, or "laser radar," (LR) as a fast, accurate, and non-contact tool for the measurement of the radius of curvature (RoC) of large mirrors. We report the results of a demonstration of this concept using a commercial laser radar system. We measured the RoC of a 1.4m x 1m spherical mirror with a nominal RoC of 4.6 m with a manufacturing tolerance of 4600mm +/- 6mm. The prescription of the mirror is related to its role as ground support equipment used in the test of part of the James Webb Space Telescope (JWST). The RoC of such a large mirror is not easily measured without contacting the surface. From a position near the center of curvature of the mirror, the LIDAR scanned the mirror surface, sampling it with 1 point per 3.5 sq cm. The measurement consisted of 3983 points and lasted only a few minutes. The laser radar uses the LIDAR signal to provide range, and encoder information from angular azimuth and elevation rotation stages provide the spherical coordinates of a given point. A best-fit to a sphere of the measured points was performed. The resulting RoC was within 20 ppm of the nominal RoC, also showing good agreement with the results of a laser tracker-based, contact metrology. This paper also discusses parameters such as test alignment, scan density, and optical surface type, as well as future possible application for full prescription characterization of aspherical mirrors, including radius, conic, off-axis distance, and aperture.

Description: Challenges in fabrication and testing have historically limited the choice of surfaces available for the design of reflective optical instruments. Spherical and conic mirrors are common, but, for future science instruments, more degrees of freedom are necessary to meet challenging performance and packaging requirements. These instruments will be composed of unusual aspheres located far off-axis with large spherical departure, and some designs will require asymmetric surface profiles. In particular, single-surface astigmatism correction in spectrographs necessitates a toroidal surface, which lacks an axis of rotational symmetry. We describe the design, fabrication, optical testing, and performance of three rotationally symmetric, off-axis, aspheric mirrors and one toroidal, off-axis, biconic camera mirror on aluminum substrates for the Infrared Multi-Object Spectrograph (IRMOS) instrument. IRMOS is a facility instrument for the Kitt Peak National Observatory's Mayall Telescope (3.8 m) and an engineering prototype for a possible design of the Next Generation Space Telescope/Multi-Object Spectrograph. The symmetric mirrors range in aperture from 94x86 mm to 286x269 mm and in f-number from 0.9 to 2.4. They are various off-axis, convex and concave, prolate and oblate ellipsoids. The concave biconic mirror has a 94x76 mm aperture, Rx=377 mm, kx=0.0778, Ry=407 mm, and ky=0.1265 and is decentered. by -2 mm in x and 227 mm in y. The mirrors have an aspect ratio of approximately 4:1. The surface error fabrication tolerances are less than 63.3 nm RMS figure error and less than 10 nm RMS microroughness. The mirrors are attached to the instrument bench via a semi-kinematic, integral flexure mount. We describe mirror design, diamond machining, the results of figure testing using computer-generated holograms, and imaging and scattered light modeling and performance.

Description: The Infrared Multi-Object Spectrograph (IRMOS) is a facility instrument for the Kitt Peak National Observatory Mayall Telescope (3.8 meter) and an engineering prototype for a potential design for the Next Generation Space Telescope/Multi-Object Spectrograph. IRMOS is a low-to mid-resolution (R = lambda/delta-lambda = 300-3800), near-IR (0.8-2.5 micron) spectrograph which produces simultaneous spectra of approximately 100 objects in its 2.8 x 2.0 arcmin field of view using a commercial MEMS multimirror array device. The instrument operating temperature is 80 K and the design is athermal --- the optical bench and mirrors are machined from aluminum 6061-T651. In spite of its baseline mechanical stress relief, aluminum 6061-T651 harbors some residual stress, which, unless relieved during fabrication, may relieve and distort mirror figure to unacceptable levels at the operating temperature. Other cryogenic instruments using aluminum mirrors for both ground-based and space IR astronomy have employed a variety of heat treatment formulae, with mixed results. We present the results of a test program designed to empirically determine the best stress relief procedure for the IRMOS mirrors. Identical test mirrors with spherical and flat optical prescriptions are processed with five different heat treatment formulae from the literature and compared to samples with out any additional processing. After figuring via diamond turning, the mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for several thermal cycles. The heat treatment procedure for the mirrors that yielded the least and most repeatable change in figure error and radius is applied to the IRMOS mirror blanks. We correlate the results of our optical testing with heat treatment and metallographic data.

Description: The Infrared Multi-Object Spectrograph (IRMOS) is a facility instrument for the Kitt Peak National Observatory Mayall Telescope (3.8 meter). IRMOS is a near-IR (0.8 - 2.5 micron) spectrograph with low to mid resolution (R=lambda/delta, lambda = 300 - 3800). The IRMOS spectrograph produces simultaneous spectra of - 100 objects in its 2.8 x 2.0 arc-min field of view using a commercial MEMS multi-mirror array device (MMA). The IRMOS optical design consists of two imaging systems, or "stages." The focal reducer, stage one, images the focal plane of the telescope onto the MMA. The spectrograph, stage two, images the MMA onto the detector. We describe the breadboard alignment method and imaging and scattered light performance for both the focal reducer and spectrograph. This testing provides verification of the optomechanical alignment method, and a measurement of the contribution of scattered light in the system due to mirror small scale surface error. After the stage I and 2 optics are integrated with the instrument, our test results will make it possible to distinguish between scattered light from the mirrors and the MMA. Image testing will be done at four wavelengths in the visible and near-IR. A mercury-argon pencil lamp will provide spectral lines at 546.1 and 1012 nm, and a blackbody radiation source lines at 1600 and 2200 nm. A CCD camera will be used as a detector for the visible wavelengths, and an IR photodiode will be used for the IR wavelengths. We compare our data with a theoretical analysis using a commercial software package. Mirror surface error is modeled by treating each surface as a superposition of various gratings (e.g., diamond turning tool marks, features due to the impurities of Al 6061, and periodic mid-frequency errors due to drift during machining).

Description: We describe the Metrology Data Processor (METDAT), the Optical Surface Analysis Code (OSAC), and their application to the image evaluation of the Far Ultraviolet Spectroscopic Explorer (FUSE) mirrors. The FUSE instrument - designed and developed by the Johns Hopkins University and launched in June 1999 is an astrophysics satellite which provides high resolution spectra (lambda/Delta(lambda) = 20,000 - 25,000) in the wavelength region from 90.5 to 118.7 nm The FUSE instrument is comprised of four co-aligned, normal incidence, off-axis parabolic mirrors, four Rowland circle spectrograph channels with holographic gratings, and delay line microchannel plate detectors. The OSAC code provides a comprehensive analysis of optical system performance, including the effects of optical surface misalignments, low spatial frequency deformations described by discrete polynomial terms, mid- and high-spatial frequency deformations (surface roughness), and diffraction due to the finite size of the aperture. Both normal incidence (traditionally infrared, visible, and near ultraviolet mirror systems) and grazing incidence (x-ray mirror systems) systems can be analyzed. The code also properly accounts for reflectance losses on the mirror surfaces. Low frequency surface errors are described in OSAC by using Zernike polynomials for normal incidence mirrors and Legendre-Fourier polynomials for grazing incidence mirrors. The scatter analysis of the mirror is based on scalar scatter theory. The program accepts simple autocovariance (ACV) function models or power spectral density (PSD) models derived from mirror surface metrology data as input to the scatter calculation. The end product of the program is a user-defined pixel array containing the system Point Spread Function (PSF). The METDAT routine is used in conjunction with the OSAC program. This code reads in laboratory metrology data in a normalized format. The code then fits the data using Zernike polynomials for normal incidence systems or Legendre-Fourier polynomials for grazing incidence systems. It removes low order terms from the metrology data, calculates statistical ACV or PSD functions, and fits these data to OSAC models for the scatter analysis. In this paper we briefly describe the laboratory image testing of FUSE spare mirror performed in the near and vacuum ultraviolet at John Hopkins University and OSAC modeling of the test setup performed at NASA/GSFC. The test setup is a double-pass configuration consisting of a Hg discharge source, the FUSE off-axis parabolic mirror under test, an autocollimating flat mirror, and a tomographic imaging detector. Two additional, small fold flats are used in the optical train to accommodate the light source and the detector. The modeling is based on Zernike fitting and PSD analysis of surface metrology data measured by both the mirror vendor (Tinsley) and JHU. The results of our models agree well with the laboratory imaging data, thus validating our theoretical model. Finally, we predict the imaging performance of FUSE mirrors in their flight configuration at far-ultraviolet wavelengths.

Description: Currently there is a strong desire to make Earth science less expensive. Freeform optics make these missions less expensive because they allow an optical designer to use fewer mirrors to create roughly the same effect. The main issue with using freeforms is how closely the substrate can be milled to its prescription. Over this summer, our team looked at two freeforms made by Corning Inc. using a brand new process to determine how close these optics are to their set prescriptions and how well NASA could align them.