Diffusion-bonded beryllium aluminum optical structures

Thomas F Grapes

doi:10.1117/12.508495

12 December 2003 Diffusion-bonded beryllium aluminum optical structures

Thomas F Grapes

Proceedings Volume 5179, Optical Materials and Structures Technologies; (2003) https://doi.org/10.1117/12.508495
Event: Optical Science and Technology, SPIE's 48th Annual Meeting, 2003, San Diego, California, United States

Abstract

Beryllium aluminum material can present significant advantages for optical support structures. A very likely advantage of beryllium aluminum compared to aluminum or titanium for such structures is its higher specific stiffness. However, beryllium aluminum material is significantly more expensive than most competing materials. The cost problem with beryllium aluminum is exacerbated if structural fabrication methods that result in near net shape parts are not used. Near net shape methods result in the least amount of material “thrown away” in the fabrication process. Casting is a primary example of near net shape manufacturing that is appropriate for certain optical support structures. Casting aluminum, and other materials as well, is common. Casting of beryllium aluminum is very difficult, however, and has not had significant success. Diffusion bonding -- a different approach for achieving near net shape beryllium aluminum optical support structures, was pursued and accomplished. Diffusion bonding is a term used to describe the joining of solid metal pieces under high temperature and pressure, but without melting. Three different optical support structures were designed and built of beryllium aluminum using diffusion bonding. Relatively small solid beryllium aluminum pieces were arranged together and then joined under hot isostatic pressure conditions. The resulting relatively large diffusion bonded part was then machined to achieve the final product. Significant cost savings as compared to machining the part from a solid block were realized. Difficulties achieving diffusion bonds in complex joints were experienced and addressed.

Citation Download Citation

Thomas F Grapes "Diffusion-bonded beryllium aluminum optical structures", Proc. SPIE 5179, Optical Materials and Structures Technologies, (12 December 2003); https://doi.org/10.1117/12.508495

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KEYWORDS

Diffusion

Aluminum

Beryllium

Solids

Metals

Optics manufacturing

Interfaces

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