Innovative high-volume low-cost manufacturing of conventional neutron supermirror beam guides, mirrors and filters for future large projects

In the next 5-10 years, the planned upgrades to the High Flux Isotope Reactor (HFIR) and the Spallation Neutron Source (SNS) neutron scattering facilities at Oak Ridge National Laboratory (ORNL) will require kilometers of new neutron supermirror beam guides, mirrors, polarizers and filters. At the same time, a comparable amount of neutron optics will be required to build the new European Spallation Source (ESS) in Sweden. These concurrent projects are stretching existing neutron manufacturers, all of which are presently located in Europe, beyond their capacities, thus presenting a unique opportunity for a new American manufacturer. We are striving to become a trusted domestic supplier for these critically needed optics, one that manufactures the highest quality supermirror optics and competes on price as well. These optics are used to direct beams of neutrons from the neutron source to various experiments where researchers from a wide array of disciplines in science and industry can use them to probe the properties of matter in unique and invaluable ways. Neutron supermirror optics consist of precisely machined substrates that are smoothed to atomic dimensions, and then are coated with thousands of precise thin-film-layers to maximize their reflectivity. We are introducing innovative new methods for smoothing substrates using proprietary cluster ion beam technology. By employing well established and highly experienced domestic suppliers, we have manufactured the first American made neutron supermirrors in over 25 years. Our phase-I project developed and tested new thin-film designs, and compared conventionally polished crystalline substrates to metal substrates treated with our cluster beam technology. The neutron reflectivity of small test samples was measured at the SNS and the results compare well with those of long established European neutron optics vendors. We have also studied the projected costs and technical issues needed for high-volume, low-cost manufacturing. Our phase-II project will continue our product development by building prototype 1-m-long sections of a rectangular-tube guide that can be used in the ôrandomizerö for the future MANTA beamline of HFIR. Such simple guides are expected to be the most ubiquitous type of neutron optic used in the new upgrades at ORNL. We will build both glass and metal guides for comparison. We also plan to collaborate with MIT Nuclear Reactor Laboratory to study the feasibility and design of advanced neutron optics such as nested mirrors, KB, and Wolters optics. Another planned innovative collaboration with the Pennington Biomedical Research Center, will attempt an innovative solution to increase our access to neutron reflectometers. Reflection measurements are critically needed to develop our products. We will develop a reflectometer using a small, moderated D-D neutron source combined with an ultrasensitive detector. This will reduce the need for the SNS to support us with extremely scarce beamtime and personnel. With this project, and with the capabilities and vast experience of our suppliers and collaborators, our goal is to qualify soon as a vendor for future neutron optics purchases. We will then expand our product line and our production to meet the increasing demand for neutron supermirror optics required for the progress of science and industry.