Design and fabrication of low-cost X-ray mirrors

Traditional X-ray mirrors made from Zerodur and silicon carbide are quite expensive because of the fabrication cost involved in achieving a very high surface finish of the order of 15 Å or better. The cost of X-ray mirrors can be greatly reduced by using replication methods for producing the grazing-incidence type mirrors. This paper presents the optical and optomechanical design for a Wolter type I mirror and its mount, and the fabrication method used to produce a low-cost replicated nickel mirror. The finite element analysis results for this mirror are also presented. The design and fabrication steps for the aluminium master mandrel used for replication are also discussed. A surface finish of better than 15 Å was achieved for a such an electroformed mirror with a wall thickness of only 1 mm.