We describe the space observatory architecture and mission design of the Single Aperture Large Telescope for Universe Studies (SALTUS) mission, a National Aeronautics and Space Administration (NASA) Astrophysics Probe Explorer concept. SALTUS will address key far-infrared science using a 14-m diameter <45 K primary reflector (M1) and will provide unprecedented levels of spectral sensitivity for planet, solar system, and galactic evolution studies and cosmic origins. Drawing from Northrop Grumman’s extensive NASA mission heritage, the observatory flight system is based on the LEOStar-3 spacecraft platform to carry the SALTUS Payload. The Payload is comprised of the inflation control system, sunshield module (SM), cold corrector module (CCM), warm instrument electronics module, and primary reflector module (PRM). The 14-m M1 is an off-axis inflatable membrane radiatively cooled by a two-layer sunshield (∼1000 m2 per layer). The CCM corrects for residual aberration from M1 and delivers a focused beam to two instruments—the High-Resolution Receiver (HiRX) and SAFARI-Lite. The CCM and PRM reside atop a truss-based composite deck that also provides a platform for the attitude control system. The SALTUS 5-year mission lifetime is driven by a two-consumable architecture: the propellant system and the inflation control system. The core interface module (CIM), a multi-faceted composite truss structure, provides a load path with high stiffness, mechanical attachment, and thermal separation between the Payload and spacecraft. The SM attaches outside the CIM with its aft end integrating directly to the bus. The spacecraft maintains an attitude off M1’s boresight with respect to the Sun line to facilitate the <45 K thermal environment. SALTUS will reside in a Sun–Earth halo L2 orbit with a maximum Earth slant range of 1.8 million km, thereby reducing orbit transfer delta-v. The instantaneous field of regard provides two continuous 20 deg viewing zones around the ecliptic poles, resulting in full sky coverage in 6 months.
The use of thin-film membranes is of considerable interest for lightweight mirror applications. The low areal density makes them ideal for large aperture imaging applications. One type of setup looked into in the past has been the lenticular design, which consists of a clear canopy attached to a reflective film that uses positive pressure to set the curvature of the mirror. One drawback to this concept has been the fact that too much error was introduced during the pass through the canopy due to material inhomogeneities and poor optical properties. This is no longer an issue thanks to developments over the past several years in the field of optical-quality polymer development. Thin-films (< 24 microns) can now be routinely made with surface roughness, thickness variation, and very good transmission properties well within specification for many visible and IR applications. The next step in this developmental process has been maintaining a prescribed figure in the mirror. This paper summarizes the current efforts in fabricating and testing a 1-meter class lenticular membrane mirror system utilizing active boundary control and stress-coating applications to form a usable aperture for visible imaging applications.
Large aperture optical quality primary mirrors have been developed which are extremely lightweight (areal densities less than 1kg/m2) made from stretched reflective polymer membranes. However, aberrations induced by boundary support errors and pressurization of a flat membrane do not produce a perfect parabolic shape. Modeling studies have shown that active boundary control can be very effective in correcting certain types of figure errors typically seen in membrane mirrors. This paper validates these design studies by applying boundary control on a 0.25-meter pressure augmented membrane mirror (PAMM). The 0.25 meter PAMM was fabricated as a pathfinder for a larger prototype. A combination of displacement actuators and electrostatic force actuators were used to control the shape of the mirror. A varied thickness stress coating prescription was developed by a SRS/AFRL team using nonlinear membrane theory. Based on modeled data, the stress coating should force the membrane into a parabolic shape when pressurized, as opposed to a spherically aberrated shape characteristic of a pressurized flat membrane. Test data from the 0.25-meter PAMM proved that the varied thickness stress coating allows for a better shape than the uniform coating.
TRS is developing new actuators based on single crystal piezoelectric materials such as Pb(Zn1/3Nb2/3)1-xTixO3 (PZN-PT) and Pb(Mg1/3Nb2/3)x-1TixO3 (PMN-PT) which exhibit very high piezoelectric coefficients (d33 = 1800-2200 pC/N) and electromechanical coupling factors (k33 > 0.9), respectively, for a variety of applications, including active vibration damping, active flow control, high precision positioning, ultrasonic motors, deformable mirrors, and adaptive optics. The d32 cut crystal plate actuators showed d32 ~ -1600 pC/N, inter-digital electroded (IDE) plate actuators showed effective d33 ~ 1100 pC/N. Single crystal stack actuators with stroke of 10 μm-100 μm were developed and tested at both room temperature and cryogenic temperatures. Flextensional single crystal piezoelectric actuators with either stack driver or plate driver were developed with stroke 70 μm - > 250 μm. For large stroke cryogenic actuation (> 1mm), a single crystal piezomotor was developed and tested at temperature of 77 K-300K and stroke of > 10mm and step resolution of 20 nm were achieved. In order to demonstrate the significance of developed single crystal actuators, modeling on single crystal piezoelectric deformable mirrors and helicopter flap control using single crystal actuators were conducted and the modeling results show that more than 20 wavelength wavefront error could be corrected by using the single crystal deformable mirrors and +/- 5.8 ° flap deflection will be obtained for a 36" flap using single crystal stack actuators.
Materials and processes have been developed for production of polymer membranes with optical quality surface characteristics. These materials have been successfully used to manufacture large, high quality, ultra lightweight, optical flats for beam splitters, lens covers and other applications. These materials can potentially be used to develop large aperture primary mirrors with areal densities less than 1kg/m2. However, for curved mirrors it is more difficult to establish and maintain desired optical figure from the initial packaged configuration. This paper describes design analysis being performed to support fabrication of a membrane mirror test article. Modeling was performed to evaluate the effectiveness of several different boundary control concepts for correcting different types of figure aberrations. Analyses of different combinations of boundary displacement actuators, electrostatic force actuators, and pressure are presented.
The Air Force Research Laboratory, Directed Energy Directorate, together with SRS Technologies Inc., Huntsville, AL, and Surface Optics Corporation, San Diego, CA, have developed meter-class optical quality membranes with dielectric coatings and custom spectral filtering. The windows range in thickness from 5 to 20 µm and can operate in the visible and the near-infrared. To date the largest membrane manufactured is slightly less than one meter in diameter and its optical thickness variation is on the order of 35 nanometers rms. Surface roughness, optical density, and other optical data will be presented. The intent of this article is to expose this technology to optical designers with the expectation that significant design opportunities for observatories, telescopes, and experiments will result.
Significant advances have been achieved in manufacturing optical quality membrane materials with surface quality suitable for use as first surface mirrors. These materials have been used to fabricate test articles demonstrating diffraction limited performance in the laboratory environment. These mirrors are supported using heavy rigid fixtures and pressure forces to tension the membrane. A lighter weight system is required to transition the membrane mirror technology to space hardware applications. Using electrostatic forces to tension and figure the membrane is one promising approach to developing a flight weight membrane mirror system. This paper discusses the design and testing of an experimental membrane mirror system that was developed to evaluate the potential areal density, figure accuracy and stability of a lightweight electrostatically figured mirror manufactured from precision cast optical quality membrane material.
There is a significant amount of research devoted to developing materials and processes for spaceborne mirrors. Carbon fiber mirrors and advanced ceramic mirrors such as SiC are being developed. These materials provide excellent stiffness to weight ratios and thermal stability. The principal problem with using these lightweight materials for mirrors is the difficulty of polishing the surface to achieve the required optical quality finish. Carbon fiber mirrors also suffer from fiber print through and ceramic mirrors are difficult and costly to polish due to the material hardness and porosity. SRS has been developing processes for depositing a very thin, optical-quality membrane layer of space-qualified polymer onto the surface of a mirror still in a rough-polished state to eliminate the need for expensive and time consuming final surface finishing of lightweight mirrors. By flow casting a polymer onto the surface, remaining peaks and valleys are filled in resulting in an extremely smooth surface. Initial research has shown that the membrane mirror surface can have a significantly better surface finish than the casting substrate, thus eliminating the need for costly final polishing.
Previous research has demonstrated the feasibility of manufacturing polymer membranes with surfaces suitable for use as optical elements on scales up to 1.5 meters. These membranes have optical surface finishes characterized by a roughness of 1.2 nanometers (rms) and mid spatial frequency figure errors (caused by thickness variations) of approximately 350 nanometers-adequate for many optical applications. With optical quality membranes fabrication demonstrated, the next technical challenges that must be met before large-aperture, ultra-light membrane mirrors can be practically achieved are to develop (1) light-weight deployable support structures, (2) the ability to control the global figure of large optical quality membranes, and (3) an improved understanding of the effects of membrane material properties (e.g., material in-homogeneities, coatings, and boundary conditions) on global figure.
The work reported herein further characterizes several key system properties and their effects on optical aberrations. This analysis helps establish technical requirements for membrane optical systems and provides additional insight required to optimize deployable support structures capable of providing passive figure control for membrane optical elements. The results are also used to investigate the need for an electrostatic control system that can actively control the figure of a large membrane mirror.
SRS Technologies has made significant strides in the research and development of ultra-lightweight membrane optics for future imaging applications while conducting work with NASA Marshall Space Flight Center and the Air Force Research Lab. Thin film mirrors have been manufactured using surface replication casting of CP1, a polyimide material developed specifically for space applications. In the course of such efforts processing and manufacturing techniques have been developed to produce polyimide membranes with surface roughness below 1.5 nanometers rms and sub-wavelength thickness variation for both curved and flat membranes. This has led to the production of membranes optically flat to (lambda) /13 ((lambda) equals 633 nm) and curved membranes with figure error on the order of microns over half-meter diameters. This accuracy places such membranes within the demonstrated correctable range of several advanced wavefront correction technologies.
The Integrated Optical Design Analysis (IODA) program is a software tool being developed to support concurrent engineering design of complex optical systems. IODA provides seamless data fusion between thermal, structural, and optical models used to design the system. The software architecture was developed by reviewing current design processes and developing software to automate the existing procedures. IODA significantly reduces the design iteration cycle time and eliminates many potential sources of error.
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