Table Of ContentLibrary of Congress Cataloging-in-Publication Data
Names: Hausner, Michael, author.
Title: Optics inspections and tests : a guide for optics inspectors and designers /
Michael Hausner.
Description: Bellingham, Washington : SPIE Press, [2017] | ©2017 | Includes
bibliographical references and index.
Identifiers: LCCN 2016006977 (print) | LCCN 2016009108 (ebook) | ISBN
9781510601796 (softcover) | ISBN 1510601791 (softcover) | ISBN 9781510601802
(pdf) | ISBN 9781510601819 (epub) | ISBN 9781510601826 (mobi)
Subjects: LCSH: Optical materials Quality control. | Optical materials Testing.
Classification: LCC QC374 .H38 2016 (print) | LCC QC374 (ebook) | DDC
621.36028/7 dc23
LC record available at http://lccn.loc.gov/2016006977
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Copyright © 2017 Society of Photo-Optical Instrumentation Engineers (SPIE)
All rights reserved. No part of this publication may be reproduced or distributed in
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Thecontentofthisbookreflectstheworkandthoughtoftheauthor.Everyefforthas
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reliance thereon.
Printed in the United States of America.
First Printing.
For updates to this book, visit http://spie.org and type “PM269” in the search field.
Contents
Preface xiii
Acknowledgments xv
I Theory and Materials 01
1 Introduction 03
1.1 Prologue 03
1.2 Defining Quality 04
1.3 Relating Quality with Optics Inspections and Testing 05
1.4 The Purpose of This Book 06
2 Optics 07
2.1 History and Development 07
2.2 The Nature of Light 09
2.3 Geometrical Optics 11
2.3.1 Scattering 12
2.3.2 Critical angle and total internal reflection 13
2.4 Physical Optics 15
2.5 Optical Aberrations 16
2.5.1 Chromatic aberrations 16
2.5.2 Monochromatic aberrations 17
2.5.3 Correcting (reducing) optical aberrations 20
2.5.4 Surface and material aberrations 22
2.5.5 Optical system aberrations 22
2.6 Interference 22
2.7 Optical System Design 25
2.8 Types of Optical Components 27
References 32
3 Raw Materials for Producing Optical Elements 33
3.1 What Is an Optical Material? 33
3.2 Materials for Optical Elements 33
3.2.1 Glass 34
3.2.1.1 Optical glass 34
3.2.1.2 Color optical filter 36
v
vi Contents
3.2.1.3 Special glasses for molding 36
3.2.2 Crystal 38
3.2.3 Plastic 39
3.2.4 Metals (for mirrors only) 40
3.2.5 Special materials 40
3.3 Classification of Optical Materials 41
3.3.1 According to molecular structure 41
3.3.2 According to atomic orientation 41
3.3.3 According to the working spectral range 42
3.3.4 According to colors 43
3.3.5 According to the refraction index (for glasses) 44
3.4 Main Characteristics of Optical Materials 44
3.4.1 Optical properties 44
3.4.2 Internal (bulk) quality 45
3.4.3 Chemical properties 46
3.4.4 Mechanical properties 48
3.4.5 Electrical properties 49
References 50
4 Manufacturing Processes of Optical Materials 51
4.1 Introduction 51
4.2 Glass Manufacturing Process 51
4.3 Crystal 54
4.3.1 Sapphire manufacturing methods 55
4.3.2 Gradient solidification method 56
4.3.3 Czochralski method 58
4.4 Chemical Vapor Deposition 59
4.4.1 Types of CVD processes 60
4.4.2 Basic steps of the CVD process 60
4.4.3 CVD system 60
4.4.4 Hot isostatic press 61
4.5 Plastic 62
4.5.1 CR-39 63
4.5.2 Related concepts 64
4.6 Aluminum 64
4.6.1 Related concepts 65
References 67
5 Methods for Producing Optical Components 69
5.1 Introduction 69
5.2 Conventional Method: Spindle Grinding and Polishing 69
5.3 Diamond Turning 71
5.4 Precision Glass Molding and Precision Molded Optics 73
5.5 Additional Methods for Improving Optical Elements 76
Contents vii
5.5.1 Magneto rheological finishing 76
5.5.2 Hybrid molding 78
5.5.3 Computer-numerical-control grinding and polishing method 79
5.5.4 Freeform polishing method 80
5.5.5 Ion beam figuring 82
5.6 Additional Shaping Methods and Those that Produce
Specular Surfaces 83
References 84
6 Optical Coatings 87
6.1 Classification of Optical Coatings 87
6.2 Materials 88
6.3 AR Coating 88
6.4 Reflective Coatings 90
6.5 Optical-Coating-Deposition Technologies 92
6.5.1 Evaporation (deposition) methods 92
6.5.2 Sputter deposition methods 94
6.5.3 Advanced plasma reactive sputtering (APRS) 95
6.6 Requirements 95
6.7 Typical Spectral Curves 97
References 97
7 Optical Adhesives 99
7.1 Introduction 99
7.2 Production Bond Failures 101
7.3 Incoming Failure Identification 103
References 104
8 Optics Standards and General Technical Specifications 105
8.1 Introduction 105
8.2 The Importance and Utility of Standards and Specifications 105
8.3 Defining a Standard 106
8.4 Defining a Specification 107
8.5 MIL-HDBK, MIL-STD, and Milspecs 108
8.6 International Organization for Standardization 110
8.7 ANSI, ASTM, and ASME 114
8.8 Deutsches Institut für Normung 115
8.9 General Standards for Technical Drawings 115
9 Metrology: Measurement Theory 117
9.1 Definition 117
9.2 Scientific or Fundamental Metrology 118
9.3 Applied, Technical, and Industrial Metrology 118
9.4 Legal Metrology 118
9.5 Geometric Dimensioning and Tolerancing 119
viii Contents
9.6 Rules of Thumb for Measurement Tools 120
References 121
II Methods and Tools 123
10 Testing and Examining Optical Components 125
10.1 Introduction 125
10.2 Overview of Production Requirement Documents 126
10.3 A Review of Quality Production and Inspection Records 126
10.3.1 Process report 127
10.3.2 Inspection report 127
10.3.3 Raw material certificates (or certificate and meld data) 128
10.3.4 Routing card 132
10.3.5 COC, COT, and COA 135
11 Inspection and Testing of Raw Materials 139
11.1 Index of Refraction 139
11.2 Homogeneity 145
11.2.1 Designation of required homogeneity in
production files 150
11.2.2 Homogeneity designation according to ISO 10110-4 152
11.3 Bubbles and Inclusions 152
11.4 Striae 152
11.4.1 Designation of required striae in production files 156
11.5 Strain (Stress) 158
11.5.1 Designation of required stress birefringence in
production files 167
11.6 Transmission/transmittance 167
11.7 Resistivity of Silicon or Germanium 170
References 172
12 Inspection and Testing of Components 177
12.1 Radius of a Spherical Surface 179
12.2 Sag (Sagitta) 204
12.3 Centration 209
12.4 Dial Gauges and Indicators 224
12.5 Roundness (Circularity) 224
12.6 Central Thickness of a Lens 233
12.7 Thickness and Parallelism of Windows 242
12.8 Length between Ground Surfaces 247
12.9 Concentricity 249
12.10Perpendicularity 255
12.11Chamfer 259
12.12Inside Edges 263
12.13Surface Texture 265
Contents ix
12.14Angularity 272
13 Inspection and Testing of Surface Shape and Figure 283
13.1 Test Plate 285
13.2 Analyzing the Interference Pattern Revealed by the
Test Plate 288
13.3 Example Surface Patterns of Flat and Spherical Surfaces 290
13.4 Principles of Manual Analysis of Interferograms 295
13.5 Analyzing the Interference of Simple Patterns 298
13.6 Analyzing the Interference of Various Patterns 302
13.7 Important Considerations when Analyzing Interference 306
13.8 Interferometric Measurements for Flat and Spherical Surfaces 308
13.9 Testing Cylindrical Surfaces 314
References 321
14 Coatings 325
14.1 Optical Properties 325
14.2 Environmental Durability 334
14.3 Visual Inspections 337
14.4 Witness Samples 338
14.5 Durability of Coatings with Primers and Silicon Removers 345
References 346
15 Special Properties of Aspheric Surfaces, Diffractive Surfaces,
and Sapphire 347
15.1 Aspheric Surfaces 347
15.1.1 Profile plots 348
15.1.2 Contact profilometer method by OptiPro 359
15.1.3 Noncontact 3D method 361
15.1.4 Roughness 362
15.1.5 Slope error 367
15.2 Diffractive Surfaces 369
15.2.1 Measuring and testing diffractive surfaces 371
15.3 Sapphire 375
References 381
III Inspection and Quality Assurance 383
16 Acceptance Sampling (Standards and Methods) 385
16.1 Introduction 385
16.2 Terms and Definitions 385
16.3 How to Determine if 100% Inspection is Necessary 386
16.4 Sampling Plan Procedure 387
16.5 Types of Decisions 387
16.6 Main Statistical Inspection Sample Table References 388
16.7 Summary 391
