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Proceedings Paper

Cost effective aluminum beryllium mirrors for critical optics applications
Author(s): Carissa Say; Jack Duich; Chris Huskamp; Ray White
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Paper Abstract

The unique performance of aluminum-beryllium frequently makes it an ideal material for manufacturing precision optical-grade metal mirrors. Traditional methods of manufacture utilize hot-pressed powder block in billet form which is subsequently machined to final dimensions. Complex component geometries such as lightweighted, non-plano mirrors require extensive tool path programming, fixturing, and CNC machining time and result in a high buy-to-fly ratio (the ratio of the mass of raw material purchased to the mass of the finished part). This increases the cost of the mirror structure as a significant percentage of the procurement cost is consumed in the form of machining, tooling, and scrap material that do not add value to the final part. Inrad Optics, Inc. and IBC Advanced Alloys Corp. undertook a joint study to evaluate the suitability of investment-cast Beralcast® 191 and 363 aluminum-beryllium as a precision mirror substrate material. Net shape investment castings of the desired geometry minimizes machining to just cleanup stock, thereby reducing the recurring procurement cost while still maintaining performance. The thermal stability of two mirrors, (one each of Beralcast® 191 and Beralcast® 363), was characterized from -40°F to +150°F. A representative pocketed mirror was developed, including the creation of a relevant geometry and production of a cast component to validate the approach. Information from the demonstration unit was used as a basis for a comparative cost study of the representative mirror produced in Beralcast® and one machined from a billet of AlBeMet® 162 (AlBeMet® is a registered trademark of Materion Corporation). The technical and financial results of these studies will be discussed in detail.

Paper Details

Date Published: 30 September 2013
PDF: 8 pages
Proc. SPIE 8837, Material Technologies and Applications to Optics, Structures, Components, and Sub-Systems, 883706 (30 September 2013); doi: 10.1117/12.2021480
Show Author Affiliations
Carissa Say, Inrad Optics (United States)
Jack Duich, Inrad Optics (United States)
Chris Huskamp, IBC Advanced Alloys (United States)
Ray White, IBC Advanced Alloys (United States)


Published in SPIE Proceedings Vol. 8837:
Material Technologies and Applications to Optics, Structures, Components, and Sub-Systems
Joseph L. Robichaud; Matthias Krödel; William A. Goodman, Editor(s)

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