Elimination of surface/subsurface defects on additively manufactured AlSi10Mg mirrors through nano-second laser irradiation.

Metal mirrors have attracted increasing attention for satisfying the growing demands for high-performance optics in airborne and spaceborne remote sensing systems. Additive manufacturing has enabled the development of metal mirrors with reduced weight and improved strength. AlSi10Mg is the most widely used metal for additive manufacturing. Diamond cutting is an effective method for obtaining nanometer-scale surface roughness. However, the surface/subsurface defects of additively manufactured AlSi10Mg deteriorate the surface roughness. Conventionally, AlSi10Mg mirrors used in near-infrared and visible systems are plated with NiP layers to improve the surface polishing performance; however, this leads to the bimetallic bending because of the different coefficients of thermal expansion between the NiP layers and AlSi10Mg blanks. In this study, a method of nanosecond-pulsed laser irradiation is proposed to eliminate the surface/subsurface defects of AlSi10Mg. The microscopic pores, unmolten particles and two-phase microstructure of the mirror surface were eliminated. The mirror surface exhibited better polishing performance, and it could be smoothly polished to a nanometer-scale surface roughness. The mirror exhibits strong temperature stability owing to the elimination of the bimetallic bending caused by the NiP layers. It is expected that the mirror surface fabricated in this study can satisfy the requirements for near-infrared or even visible applications.