arXiv subjects

Wenjuan Sun

Publications and source records attributed to Wenjuan Sun.

3 recordsLinked to original sources

arXiv2026

Laser Remelting for Reduced Porosity on Additively Manufactured Aluminium Mirrors

Additively manufactured (AM) AlSi10Mg mirrors are fabricated through laser powder bed fusion (LPBF), allowing the use of complex geometries such as lattices and organic structures that enable high mass reduction while maintaining mechanical stiffness. Micron-sized pores that cause optical scatter may form during LPBF as a consequence of deviations from the optimal processing window, particularly from laser energy input and scan strategy. This work proposes a laser remelting strategy aimed at reducing porosity; standard LPBF build steps automatically alternate with laser remelting passes, where previously deposited material is remelted during fabrication. Laser remelting is evaluated through fabricating 10 mm proof-of-concept cubes. Following single point diamond turning (SPDT), optical measurements characterised surface roughness and identified surface artefacts. The best-performing AlSi10Mg remelted cube exhibited no pores within sampled regions and achieved 6.4 nm average surface roughness, comparable to a conventionally manufactured RSA 6061 control cube (5.8 nm). Driven by these results, AM 52 mm diameter secondary sandwich mirrors were manufactured using LPBF and laser remelting. These incorporate an optimised diamond TPMS lattice to achieve a 50% mass reduction while accommodating design for AM considerations. Unlike the cube study, the optical surface of the remelted mirror after SPDT exhibited residual porosity and 11.8 nm average surface roughness. These results show that while the proof-of-concept confirmed the viability of laser remelting in reducing porosity within simple geometries, optimisation of the LPBF and SPDT processes are required to translate the benefits of laser remelting to lightweight AlSi10Mg AM mirrors.

physics.optics↗

arXiv2025

Additive manufacturing in aluminium of a primary mirror for a CubeSat application: manufacture, testing and evaluation

Additive manufacturing (AM; 3D Printing), a process which creates a part layer-by-layer, has the potential to improve upon conventional lightweight mirror manufacturing techniques, including subtractive (milling), formative (casting) and fabricative (bonding) manufacturing. Increased mass reduction whilst maintaining mechanical performance can be achieved through the creation of intricate lattice geometries, which are impossible to manufacture conventionally. Further, part consolidation can be introduced to reduce the number of interfaces and thereby points of failure. AM design optimisation using computational tools has been extensively covered in existing literature. However, additional research, specifically evaluation of the optical surface, is required to qualify these results before these advantages can be realised. This paper outlines the development & metrology of an AM mirror for a CubeSat platform with a targeted mass reduction of 60% compared to an equivalent solid body. This project aims to incorporate recent developments in AM mirror design, with a focus on manufacture, testing & evaluation. This is achieved through a simplified design process of a Cassegrain telescope primary mirror mounted within a 3U CubeSat chassis. The mirror geometry is annular with an external diameter of 84 mm and an internal diameter of 32 mm; the optical prescription is flat for ease of manufacture. Prototypes were printed in AlSi10Mg, a low-cost aluminium alloy commonly used in metal additive manufacturing. They were then machined and single-point diamond turned to achieve a reflective surface. Both quantitative & qualitative evaluations of the optical surface were conducted to assess the effect of hot isostatic pressing (HIP) on the optical surface quality. The results indicated that HIP reduced surface porosity; however, it also increased surface roughness and, consequently, optical scatter.

astro-ph.IM↗

arXiv2023

The realisation of fast X-ray computed tomography using a limited number of projection images for dimensional metrology

Due to the merit of establishing volumetric data, X-ray computed tomography (XCT) is increasingly used as a non-destructive evaluation technique in the quality control of advanced manufactured parts with complex non-line-of-sight features. However, the cost of measurement time and data storage hampers the adoption of the technique in production lines. Commercial fast XCT utilises X-ray detectors with fast detection capability, which can be expensive and results a large amount of data. This paper discussed a different approach, where fast XCT was realised via the acquisition of a small number of projection images instead of full projection images. An established total variation (TV) algorithm was used to handle the reconstruction. The paper investigates the feasibility of using the TV algorithm in handling a significantly reduced number of projection images for reconstruction. This allows a reduction of measurement time from fifty-two minutes to one minute for a typical industrial XCT system. It also enables a reduction of data size proportionally. A test strategy including both quantitative and qualitative test metrics was considered to evaluate the effectiveness of the reconstruction algorithm. The qualitative evaluation includes both the signal to noise ratio and the contrast to noise ratio. The quantitative evaluation was established using reference samples with different internal and external geometries. Simulation data were used in the assessment considering various influence factors, such as X-ray source property and instrument noise. The results demonstrated the possibility of using advanced reconstruction algorithms in handling XCT measurements with a significantly limited number of projection images for dimensional measurements.

physics.app-ph↗