Non-contact optical three dimensional liner metrology
We optically captured the "as-built" liner geometry of NTLX (near term liner experiments) for Shiva Star using ultra-precision ranging lasers. We subsequently verified the resulting digitized geometry against the 3D CAD model of the part. The results confirmed that the Liner contours are within designed tolerances but revealed subtle fabrication artifacts that would typically go undetected. These features included centimeters long waviness and saddle and bulge regions of 1 micron or less in magnitude. The laser technology typically provided 10 micron spatial resolution with /spl plusmn/12 nanometer ranging precision. Atlas liners in the future may have to be diamond turned and will have the centimeter wavelength and 100 angstrom amplitude requirements. The advantages of using laser technology are (1) it avoids surface damage that may occur with conventional contact probes and (2) dramatically improves spatial resolution over CMM, capacitance and inductance type probes. Our work is the result of a perceived future need to develop precision, non-contact, liner inspection techniques to verify geometry, characterize machining artifacts and map wall thickness on delicate diamond turned surfaces. Capturing "as-built" geometry in a non-contact way coupled with part-to-CAD verification software tools creates a new metrology competency for MST-7.
Enhanced Dual Confocal Measurement System
Abstract A measurement instrument utilizing dual, chromatic, confocal, distance sensors has been jointly developed by General Atomics and Sandia National Laboratories (SNL) for thickness and flatness measurement of target components used in dynamic materials properties (DMP) experiments on the SNL Z-Machine (Z). Compared to previous methods used in production of these types of targets, the tool saves time and yields a 4× reduction in thickness uncertainty which is one of the largest sources of error in equation of state measurements critical to supporting the National Nuclear Security Administration Stockpile Stewardship program and computer modeling of high energy density experiments. It has numerous differences from earlier instruments operating on the dual confocal sensor principle to accommodate DMP components including larger lateral travel, longer working distance, ability to measure flatness in addition to thickness, built-in thickness calibration standards for quickly checking calibration before and after each measurement, and streamlined operation. Thickness and flatness of 0.2- to 3.3-mm-thick sections of diamond-machined copper and aluminum can be measured to submicron accuracy. Sections up to 6 mm thick can be measured with as-yet undetermined accuracy. Samples must have one surface which is flat to within 300 µm, lateral dimensions of no more than 50 ×50 mm, and height less than 40 mm.
Fabrication and characterization of aluminum heavy liners for the pulse power systems of the high energy density physics program at Los Alamos
Aluminum heavy liners of three basic types have been fabricated for Los Alamos pulse power experiments. The first fabrications used a conventional hand operated lathe with high speed steel cutting tools. More recent fabrications have used numerically controlled lathes with carbide insert cutting tools. A numerically controlled Pneumo lathe with an air bearing spindle and with air bearing cross slides has been used to fabricate the most recent examples of the 3.2 gm Pegasus Precision Liner that is normally accelerated to 3 mm/{micro}s for experiments at the Pegasus II pulse power facility. The basic dimensions, including wall thickness, of fourteen of these parts have been characterized by an automated inspection machine. Liner surface finishes are measured directly by stylus profilometer and by optical interferometric analysis of cast polymeric replicas. Statistics of these measurements will be presented. Plans for future fabrication of similar and larger liners with increasingly stringent specification of wall thickness and of surface finish are described along with corresponding plans for liner characterization improvements.