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Abstract
Metal mirrors for precise optical applications are commonly fabricated by coating of a metal base substrate with a nickel-phosphorus alloy (NiP). The NiP layer is then processed by precision diamond turning and polishing to obtain a high-quality mirror surface. In this work, Ti-6Al-4V samples that were made by additive manufacturing, also called 3D printing, were used as a base for the development of metal mirrors. The additively manufactured samples were electroplated with a NiP coating and machined using single-point diamond turning (SPDT) to obtain a flat mirror with optical quality and low form error surface. The periodic structure of the SPDT toolmark was then removed by polishing postprocessing. Polishing optimization was first performed on NiP-coated aluminum test samples to find an optimal polishing setup. Based on this optimization, postprocessing of titanium samples was carried out by pitch polishing in combination with 1, 0.25, and $0.1\,\unicode{x00B5}{\rm m}$ diamond slurries. Using this polishing processing, a scratch-free surface was attained with surface microroughness below 0.5 nm.
© 2021 Optical Society of America
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