In the last 25 years, electroforming process has been extensively optimised to produce grazing incidence optics for the X-ray space telescopes, enabling the renown observatories Beppo-SAX for the Italian Space Agency, SWIFT for NASA, XMM Newton for ESA, eROSITA for MPE.These optics are made of thin Nickel mirrors that are grown by electroforming process in an electrolytic bath on a Gold coated mandrel.Mandrels are manufactured in Aluminium alloy with NiP coating, which allows, after polishing to reach very smooth roughness in the order of 0.3 nm.After separation of the mirror from the mandrel, Gold layer becomes the X-Ray optical reflecting coating, preserving the low roughness of the mandrel.The Nickel Mirror shells are nested tightly in high-performance optical structures, the X ray telescope.The electroforming cycle ranged between 40 and 100 hours, depending on the thickness of the mirrors, typically between 0.2 and 0.6 mm for the innermost and outermost shells, respectively. The average electroforming time is 65 hours per mirror, with 1 hour for assembly and preparation of the mandrel and 1 hour for separation after electroforming.Electroforming has also been adopted for production of large reflector panels for sub-millimetre radio telescope applications. These are laminated panels made of electroformed Nickel skins bonded to an Aluminium honeycomb core over a precise mould, resulting in typical shape accuracy of 8 µm at only 10 kg/m² mass density.Between 2006 and 2016, 3000 mirror panels for 25 antennas of the ALMA radio-telescope array of ESO and 1600 mirror panels for the 50-m diameter Large Millimetre Telescope (LMT) “Alfonso Serrano” of INAOE were designed, produced and tested.Electroforming replica consists of the replication of mirror substrates from high precision mandrels by means of the electroforming process.The mandrel is machined and polished to the shape accuracy and surface roughness requirements of the final mirror.In the electroforming process, the mandrel is Gold-coated by e-beam evaporation and then immersed in the electrolytic bath. Nickel ions, deposit onto the Gold-coated mandrel creating a low-stress Nickel mirror.Upon reaching the desired thickness, the mandrel is removed from the bath and the mirror is separated from the mandrel. In this process, the Gold layer is bonded to the mirror, creating an integrated reflective layer with the same roughness as the mandrel. The mandrel is then qualified for the next electroforming cycle, where another mirror is replicated from the same mandrel, and so on for the following cycles.Process cycles, key inspection points, verification and testing as part of the production cycles will be described and presented.Panoramic view of ALMA radio-telescopes. Photo courtesy of ESO. Figure 1
Read full abstract