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Objective, Dome Material/Fabrication: Mid-wave material Extreme environmental durability

This project focuses on developing a monolithic hyper-hemispherical dome material with mid-wave properties and exceptional durability for extreme environments. The technology enables accurate, high-speed optical fabrication processes in a cost-effective manner. Materials such as Spinel, Silicon, and ALON are examined for suitability. Foreign object damage testing, including rigorous simulations and projectile impact assessments, are being conducted to evaluate the material strength and improvement, particularly in ALON. Successful thermal shock tests validate the enhanced strength of ALON, showcasing advancements in its fabrication, machining, and thin-film coatings.

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Objective, Dome Material/Fabrication: Mid-wave material Extreme environmental durability

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  1. Objective, Dome Material/Fabrication: • Mid-wave material • Extreme environmental durability • Technology available to ‘form’ into a monolithic hyper-hemispherical configuration • Accurate and repeatable High-speed optical fabrication process • Cost effective combination of materials and processing

  2. Material Option(s) review: • Spinel. • Silicon • ALON

  3. Foreign Object Damage, testing: • Testing on ALON, Silicon and Fused Silica. • Being performed at UDRI • Simulate aircraft foreign object damage from take-off/landing (20 m/s to 75 m/s) • Testing being conducted by launching 3/8” diameter granite projectiles into the window samples using a .50 caliber bore compressed-gas gun. • Parts rigidly mounted at 450 AOI • A laser photodetector system has been employed to measure the projectile impact velocity • All parts are being photographed before and after test

  4. Foreign Object Damage, testing:

  5. Strength of Material, Improvement, ALON • The objective of the ALON strength enhancement program were to increase the strength of ALON so that high thermal shock resistant domes could be made. • Several years of fabrication/thermal processing development yielded a significant increase to the ultimate strength of ALON

  6. Strength of Material, Improvement, ALON Successful Thermal Shock-testing of Domes + much higher ultimate strength exhibited by equi-biaxial flexure testing of plano samples validates the modified material process’

  7. ‘Forming’, ALON

  8. ‘Green’ Machining, ALON

  9. ‘High-Speed’ Optical Fabrication, ALON

  10. Thin-film Coatings

  11. Thin-Film

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