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Abstract: The tangential curvature of actively bent X-ray mirrors at synchrotron radiation and X-ray free-electron laser (XFEL) facilities is typically only changed every few hours or even days. This operation can take tens of minutes for active optics with multiple bending actuators and often requires expert guidance using in situ monitoring devices. Hence, the dynamic performance of active X-ray optics for synchrotron beamlines has historically not been exploited. This is in stark contrast to many other scientific fields. However, many areas of synchrotron radiation and XFEL science, including macromolecular crystallography, could greatly benefit from the ability to change the size and shape of the X-ray beam rapidly and continuously. The advantages of this innovative approach are twofold: a large reduction in the dead time required to change the size of the X-ray beam for different-sized samples and the possibility of making multiple changes to the beam during the measurement of a single sample. In the preceding paper [Part I; Alcock, Nistea, Signorato & Sawhney (2019[Alcock, S. G., Nistea, I.-T., Signorato, R. & Sawhney, K. (2019). J. Synchrotron Rad. 26, this issue.]), J. Synchrotron Rad. 26, this issue], which accompanies this article, high-speed visible-light Fizeau interferometry was used to identify the factors which influence the dynamic bending behaviour of piezoelectric bimorph deformable X-ray mirrors. Building upon this ex situ metrology study, provided here is the first synchrotron radiation beamline implementation of high-speed adaptive X-ray optics using two bimorphs operating as a Kirkpatrick–Baez pair. With optimized substrates, novel opto-mechanical holders and a next-generation high-voltage power supply, the size of an X-ray beam was rapidly and repeatedly switched in <10 s. Of equal importance, it is also shown that compensation of piezoelectric creep ensures that the X-ray beam size remains stable for more than 1 h after making a major change. The era of high-speed adaptive X-ray optics for synchrotron radiation and XFEL beamlines has begun.

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Abstract: Meeting the ever-increasing performance demands of X-ray beamlines at modern synchrotrons, such as Diamond Light Source (DLS), requires the use of ultra-high-quality X-ray mirrors with surface deviations of less than a few nanometres from their ideal shape. Ion beam figuring (IBF) is frequently used for creating mirrors of this precision, but achieving the highest accuracy is critically dependent on careful alignment and precise metrology of defects on the optical surface. Multiple iterations of measurement and correction are typically required, and convergence towards the requisite shape can be a slow process. DLS have designed and built an in-house IBF system that comprises a large diameter DC gridded ion source, and a 4-axis motion stage for manipulating the mirror being figured. Additionally, a slope measuring profilometer for in-situ metrology, and an imaging system for alignment, are also built into the system. The advantages of incorporating these extra components are twofold: fast metrology feedback after each figuring run will considerably reduce the time required to perform multiple figuring iterations; and alignment and indexing errors will be drastically reduced when transferring the optic. Complemented by the Optical Metrology Laboratory at DLS and at-wavelength X-ray measurements on the Test beamline B16, it is expected that this system will enable rapid development and testing of high-quality mirrors with novel designs for micro- and nano-focussing of X-rays.

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Abstract: Additive manufacturing (AM; 3D printing) is a fabrication process that builds an object layer-upon-layer and promotes the use of structures that would not be possible via subtractive machining. Prototype AM metal mirrors are increasingly being studied in order to exploit the advantage of the broad AM design-space to develop intricate lightweight structures that are more optimised for function than traditional open-back mirror lightweighting. This paper describes a UK Space Agency funded project to design and manufacture a series of lightweighted AM mirrors to fit within a 3U CubeSat chassis. Six AM mirrors of identical design will be presented: two in aluminium (AlSi10Mg), two in nickel phosphorous (NiP) coated AlSi10Mg, and two in titanium (Ti64). For each material mirror pair, one is hand-polished and the other is diamond turned. Metrology data, surface form error and surface roughness, will be presented to compare and contrast the different materials and post-processing methods. To assess the presence of porosity, a frequent concern for AM materials, X-ray computed tomography measurements will be presented to highlight the location and density of pores within the mirror substrates; methods to mitigate the distribution of pores near the optical surface will be described. As a metric for success the AlSi10Mg + NiP and AlSi10Mg mirrors should be suitable for visible and infrared applications respectively.

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Abstract: Design for additive manufacture (AM; 3D printing) is significantly different than design for subtractive machining. Although there are some limitations on the designs that can be printed, the increase in the AM design-space removes some of the existing challenges faced by the traditional lightweight mirror designs; for example, sandwich mirrors are just as easy to fabricate as open-back mirrors via AM, and they provide an improvement in structural rigidity. However, the ability to print a sandwich mirror as a single component does come with extra considerations; such as orientation upon the build plate and access to remove any temporary support material. This paper describes the iterations in optimisation applied to the lightweighting of a small, 84mm diameter by 20mm height, spherical concave mirror intended for CubeSat applications. The initial design, which was fabricated, is discussed in terms of the internal lightweighting design and the design constraints that were imposed by printing and post-processing. Iterations on the initial design are presented; these include the use of topology optimisation to minimise the total internal strain energy during mirror polishing and the use of lattices combined with thickness variation i.e. having a thicker lattice in strategic support locations. To assess the suitability of each design, finite element analysis is presented to quantify the print-through of the lightweighting upon the optical surface for a given mass reduction.

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Abstract: Recently, the dynamic performance of piezo-electric deformable “bimorph” mirrors for synchrotron radiation and X-ray free electron laser sources has been characterized and significantly improved. This innovation enables high intensity X-ray beams to be rapidly focused or defocused to either match to the size of the sample under test or to select different sized regions of interest in larger samples. In this paper, we extend these results by monitoring a bimorph mirror using a combination of ex situ metrology instruments. Comparison between results from the Diamond-NOM (Nanometre Optical Metrology) slope profiler, a Fizeau interferometer, and Zygo ZPSTM distance measuring probes shows that bimorph X-ray mirrors can reliably and accurately be driven at 1 Hz using advanced features recently added to the high voltage (HV), bipolar “HV-Adaptos” power supply from CAEN.